Robots KR CYBERTECH With F and C Variants Specification

Transcription

1 Robots KR CYBERTECH With F and C Variants Specification Issued: Spez KR CYBERTECH V4 KUKA Deutschland GmbH

2 Copyright 2018 KUKA Deutschland GmbH Zugspitzstraße 140 D Augsburg Germany This documentation or excerpts therefrom may not be reproduced or disclosed to third parties without the express permission of KUKA Deutschland GmbH. Other functions not described in this documentation may be operable in the controller. The user has no claims to these functions, however, in the case of a replacement or service work. We have checked the content of this documentation for conformity with the hardware and software described. Nevertheless, discrepancies cannot be precluded, for which reason we are not able to guarantee total conformity. The information in this documentation is checked on a regular basis, however, and necessary corrections will be incorporated in the subsequent edition. Subject to technical alterations without an effect on the function. KIM-PS5-DOC Translation of the original documentation Publication: Pub Spez KR CYBERTECH (PDF) en PB7711 Book structure: Spez KR CYBERTECH V3.1 BS8944 Version: Spez KR CYBERTECH V4 2/181 Spez KR CYBERTECH V4 Issued:

3 Contents 1 Introduction Industrial robot documentation Representation of warnings and notes Purpose Target group Intended use Product description Overview of the robot system Description of the manipulator , overview , KR 8 R Basic data, KR 8 R Axis data, KR 8 R Payloads, KR 8 R Foundation loads, KR 8 R , KR 12 R Basic data, KR 12 R Axis data, KR 12 R Payloads, KR 12 R Foundation loads, KR 12 R , KR 16 R Basic data, KR 16 R Axis data, KR 16 R Payloads, KR 16 R Foundation loads, KR 16 R , KR 16 R Basic data, KR 16 R Axis data, KR 16 R Payloads, KR 16 R Foundation loads, KR 16 R , KR 20 R Basic data, KR 20 R Axis data, KR 20 R Payloads, KR 20 R Foundation loads, KR 20 R , KR 20 R1810 F Basic data, KR 20 R1810 F Axis data, KR 20 R1810 F Payloads, KR 20 R1810 F Foundation loads, KR 20 R1810 F , KR 20 R1810 CR Basic data, KR 20 R1810 CR Axis data, KR 20 R1810 CR Spez KR CYBERTECH V4 Issued: /181

4 4.8.3 Payloads, KR 20 R1810 CR Foundation loads, KR 20 R1810 CR , KR 22 R Basic data, KR 22 R Axis data, KR 22 R Payloads, KR 22 R Foundation loads, KR 22 R Plates and labels REACH duty to communicate information acc. to Art. 33 of Regulation (EC) 1907/ Stopping distances and times General information Terms used Stopping distances and times, KR 8 R Stopping distances and stopping times for STOP 0, axis 1 to axis Stopping distances and stopping times for STOP 1, axis Stopping distances and stopping times for STOP 1, axis Stopping distances and stopping times for STOP 1, axis Stopping distances and times, KR 12 R Stopping distances and stopping times for STOP 0, axis 1 to axis Stopping distances and stopping times for STOP 1, axis Stopping distances and stopping times for STOP 1, axis Stopping distances and stopping times for STOP 1, axis Stopping distances and times, KR 16 R Stopping distances and stopping times for STOP 0, axis 1 to axis Stopping distances and stopping times for STOP 1, axis Stopping distances and stopping times for STOP 1, axis Stopping distances and stopping times for STOP 1, axis Stopping distances and times, KR 16 R Stopping distances and stopping times for STOP 0, axis 1 to axis Stopping distances and stopping times for STOP 1, axis Stopping distances and stopping times for STOP 1, axis Stopping distances and stopping times for STOP 1, axis Stopping distances and times, KR 20 R1810 and KR 20 R1810 CRStopping distances Stopping distances and stopping times for STOP 0, axis 1 to axis Stopping distances and stopping times for STOP 1, axis Stopping distances and stopping times for STOP 1, axis Stopping distances and stopping times for STOP 1, axis Stopping distances and times, KR 22 R Stopping distances and stopping times for STOP 0, axis 1 to axis Stopping distances and stopping times for STOP 1, axis Stopping distances and stopping times for STOP 1, axis Stopping distances and stopping times for STOP 1, axis Safety General Liability Intended use of the industrial robot EC declaration of conformity and declaration of incorporation /181 Spez KR CYBERTECH V4 Issued:

5 5.1.4 Terms used Personnel Workspace, safety zone and danger zone Overview of protective equipment Mechanical end stops Mechanical axis limitation (optional) Options for moving the manipulator without drive energy Labeling on the industrial robot Safety measures General safety measures Transportation Start-up and recommissioning Manual mode Automatic mode Maintenance and repair Decommissioning, storage and disposal Applied norms and regulations Planning Information for planning Mounting base with centering Machine frame mounting Connecting cables and interfaces Transportation Transporting the robot Options Release device (optional) Booster frames KUKA Service Requesting support KUKA Customer Support Index 179 Spez KR CYBERTECH V4 Issued: /181

6 Introduction 1 Introduction 1.1 Industrial robot documentation The industrial robot documentation consists of the following parts: Documentation for the manipulator Documentation for the robot controller Operating and programming instructions for the System Software Instructions for options and accessories Parts catalog on storage medium Each of these sets of instructions is a separate document. 1.2 Representation of warnings and notes Safety These warnings are relevant to safety and must be observed. DANGER These warnings mean that it is certain or highly probable that death or severe injuries will occur, if no precautions are taken. WARNING These warnings mean that death or severe injuries may occur, if no precautions are taken. CAUTION These warnings mean that minor injuries may occur, if no precautions are taken. NOTICE These warnings mean that damage to property may occur, if no precautions are taken. Notices These warnings contain references to safety-relevant information or general safety measures. These warnings do not refer to individual hazards or individual precautionary measures. This warning draws attention to procedures which serve to prevent or remedy emergencies or malfunctions: SAFETY INSTRUCTION The following procedure must be followed exactly! Procedures marked with this warning must be followed exactly. These notices serve to make your work easier or contain references to further information. Tip to make your work easier or reference to further information. 6/181 Spez KR CYBERTECH V4 Issued:

7 2 Purpose 2.1 Target group Purpose This documentation is aimed at users with the following knowledge and skills: Advanced knowledge of mechanical engineering Advanced knowledge of electrical and electronic systems Knowledge of the robot controller system For optimal use of our products, we recommend that our customers take part in a course of training at KUKA College. Information about the training program can be found at or can be obtained directly from our subsidiaries. 2.2 Intended use Use Misuse The industrial robot is intended for handling tools and fixtures or for processing and transferring components or products. Use is only permitted under the specified environmental conditions. Any use or application deviating from the intended use is deemed to be misuse and is not allowed. This includes e.g.: Use as a climbing aid Operation outside the specified operating parameters Operation without the required safety equipment NOTICE Changing the structure of the robot, e.g. by drilling holes, can result in damage to the components. This is considered improper use and leads to loss of guarantee and liability entitlements. NOTICE Deviations from the operating conditions specified in the technical data or the use of special functions or applications can lead to premature wear. KUKA Deutschland GmbH must be consulted. The robot system is an integral part of a complete system and may only be operated in a CE-compliant system. Spez KR CYBERTECH V4 Issued: /181

8 Product description 3 Product description 3.1 Overview of the robot system A robot system (>>> Fig. 3-1) comprises all the assemblies of an industrial robot, including the manipulator (mechanical system and electrical installations), control cabinet, connecting cables, end effector (tool) and other equipment. The KR CYBERTECH product family comprises the robot variants: KR 8 R2010 KR 12 R1810 KR 16 R1610 KR 16 R2010 KR 20 R1810 KR 20 R1810 F KR 20 R1810 CR KR 22 R1610 The KR 20 R1810 F and KR 20 R1810 CR have additional corrosion prevention measures in the form of stainless steel components and screws. An industrial robot of this product family comprises the following components: Manipulator Robot controller Connecting cables KUKA smartpad teach pendant Software Options, accessories Fig. 3-1: Example of a robot system 1 Manipulator 3 Robot controller 2 Connecting cables 4 Teach pendant, KUKA smart- PAD 8/181 Spez KR CYBERTECH V4 Issued:

9 3.2 Description of the manipulator Overview The manipulators (manipulator = robot arm and electrical installations) (>>> Fig. 3-2) of the KR CYBERTECH robot family are designed as 6-axis jointed-arm kinematic systems. They consist of the following principal components: Product description In-line wrist Link arm Rotating column Base frame Electrical installations Fig. 3-2: Main assemblies of the manipulator 1 Link arm 4 Rotating column 2 In-line wrist/arm 5 Base frame 3 Electrical installations Axes 1 to 3 are equipped with end stops. These serve only as machine protection. There are two options available for personnel protection: The Safe Robot functionality of the controller The use of mechanical axis limitations for axes 1 to 3 (optional) In-line wrist The robot can be equipped with a 3-axis in-line wrist/arm combination. This arm/in-line wrist assembly is screwed directly to the link arm of the robot via gear unit A3. This in-line wrist/arm assembly is available in two length variants. End effectors are attached to the mounting flange of axis 6. Axes A1 to A5 have a measuring device, through which the mechanical zero of the respective axis can be checked by means of an electronic probe (accessory) and transferred to the controller. For axis A6, a vernier is available for locate the mechanical zero position. Directions of rotation, axis data and permissible loads can be found in the chapter (>>> 4 "Technical data" Page 11). Spez KR CYBERTECH V4 Issued: /181

10 Product description Link arm Rotating column Base frame The in-line wrist is driven by the motors inside the in-line wrist. Power is transmitted within the in-line wrist directly by gear unit A4 for axis 4; for axes 5 and 6, gear units with bevel gears and a toothed belt stage are used. The mounting flange conforms, with minimal deviations, to ISO :2004. The link arm is the assembly located between the arm and the rotating column. It consists of the link arm body with the buffers for axis 2 and the measurement notch for axis 3. The link arm is available in two length variants. The rotating column houses the gear units and motors A1 and A2. The rotational motion of axis 1 is performed by the rotating column. This is screwed to the base frame via the gear unit of axis 1 and is driven by a motor in the rotating column. The link arm is also mounted in the rotating column. The base frame is the base of the robot. It is screwed to the mounting base. The flexible tube for the electrical installations is installed in the base frame. Also located on the rear of the base frame are the junction box for the motor and data cable and the energy supply system. Electrical installations Options The electrical installations include all the motor and data cables for the motors of axes 1 to 6. All connections are implemented as connectors in order to enable the motors to be exchanged quickly and reliably. The electrical installations also include the combo box, which is fastened to the base frame. The combo box contains the RDC and all necessary connections for robot operation. The electrical installations also include a protective circuit. The robot can be fitted and operated with various options, e.g.: Energy supply systems, axes 1 to 3 Energy supply systems, axes 3 to 6 Axis limitations for axes A1, A2 and A3 Booster frames The options are described in separate documentation. 10/181 Spez KR CYBERTECH V4 Issued:

11 4 4.1, overview The technical data for the individual robot types can be found in the following sections: Robot KR 8 R2010 (>>> 4.2 ", KR 8 R2010" Page 12) Plates and labels (>>> 4.10 "Plates and labels" Page 100) Stopping distances and times KR 12 R1810 (>>> "Stopping distances and times, KR 8 R2010" Page 104) (>>> 4.3 ", KR 12 R1810" Page 23) Plates and labels (>>> 4.10 "Plates and labels" Page 100) Stopping distances and times KR 16 R1610 (>>> "Stopping distances and times, KR 12 R1810" Page 109) (>>> 4.4 ", KR 16 R1610" Page 34) Plates and labels (>>> 4.10 "Plates and labels" Page 100) Stopping distances and times KR 16 R2010 (>>> "Stopping distances and times, KR 16 R1610" Page 115) (>>> 4.5 ", KR 16 R2010" Page 45) Plates and labels (>>> 4.10 "Plates and labels" Page 100) Stopping distances and times KR 20 R1810 (>>> "Stopping distances and times, KR 16 R2010" Page 121) (>>> 4.6 ", KR 20 R1810" Page 56) Plates and labels (>>> 4.10 "Plates and labels" Page 100) Stopping distances and times KR 20 R1810 CR (>>> "Stopping distances and times, KR 20 R1810 and KR 20 R1810 CRStopping distances" Page 127) (>>> 4.8 ", KR 20 R1810 CR" Page 78) Plates and labels (>>> 4.10 "Plates and labels" Page 100) Spez KR CYBERTECH V4 Issued: /181

12 Robot Stopping distances and times KR 22 R1610 (>>> "Stopping distances and times, KR 20 R1810 and KR 20 R1810 CRStopping distances" Page 127) (>>> 4.9 ", KR 22 R1610" Page 89) Plates and labels (>>> 4.10 "Plates and labels" Page 100) Stopping distances and times (>>> "Stopping distances and times, KR 22 R1610" Page 133) 4.2, KR 8 R Basic data, KR 8 R2010 Basic data Number of axes 6 Number of controlled axes 6 KR 8 R2010 Volume of working envelope 32.5 m³ Pose repeatability (ISO 9283) Weight Rated payload Maximum payload Maximum reach Protection rating (IEC 60529) Protection rating, in-line wrist (IEC 60529) Sound level Mounting position Footprint Hole pattern: mounting surface for kinematic system Permissible angle of inclination - ± 0.04 mm approx. 255 kg 8 kg 9.7 kg 2013 mm IP65 IP65 < 75 db (A) Floor; Ceiling; Wall; Desired angle mm x 370 mm S260 Default color Base frame: black (RAL 9005); Moving parts: KUKA orange 2567 Controller Transformation name KR C4 KR C4: KR8R2010 C4 12/181 Spez KR CYBERTECH V4 Issued:

13 Ambient conditions Connecting cables Humidity class (EN 60204) - Classification of environmental conditions (EN ) Ambient temperature 3K3 During operation 5 C to 55 C (278 K to 328 K) During storage/transportation -20 C to 60 C (253 K to 333 K) For operation at low temperatures, it may be necessary to warm up the robot. Cable designation Connector designation robot controller - robot Interface with robot Motor cable X20 - X30 Han-Yellock 60 Data cable X21 - X31 HAN Q12 Ground conductor / equipotential bonding 16 mm 2 (optional) M8 ring cable lug at both ends Cable lengths Standard Minimum bending radius 4 m, 7 m, 15 m, 25 m, 35 m, 50 m 5x D For detailed specifications of the connecting cables, see Description of the connecting cables Axis data, KR 8 R2010 Axis data Motion range A1 ±185 A2-185 / 65 A3-138 / 175 A4 ±350 A5 ±130 A6 ±350 Speed with rated payload A1 200 /s A2 175 /s A3 190 /s A4 430 /s A5 430 /s Spez KR CYBERTECH V4 Issued: /181

14 A6 630 /s The direction of motion and the arrangement of the individual axes may be noted from the following diagram. Fig. 4-1: Direction of rotation of robot axes Mastering positions Mastering position A1 27 A2 90 A3 90 A4 0 A5 0 A6 0 Working envelope The following diagrams show the shape and size of the working envelope for these variants of this product family. The reference point for the working envelope is the intersection of axes 4 and 5. 14/181 Spez KR CYBERTECH V4 Issued:

15 Fig. 4-2: Working envelope, side view, KR 8 R2010 Fig. 4-3: Working envelope, top view, KR 8 R2010 Inclined installation The robot can installed anywhere from a 0 position (floor) to a 180 position (ceiling). The following figure shows the possible limitation of the motion range of axis 1, as a function of the angle of inclination of the robot. The inclination angles for the robot must be entered correctly into the controller if the robot is not operated in the floor-mounted position. Configuration of the angles is possible via WorkVisual. The inclination angles for an unchanged main working direction of the robot: Spez KR CYBERTECH V4 Issued: /181

16 Floor: A:0, B:0, C:0 Wall: A:0, B:90, C:0 Ceiling: A:0, B:0, C:180 CAUTION The inclined installation angles must be individually checked and entered. An incorrectly entered inclined installation angle can lead to unforeseen motion and/or to an overload and, potentially, damage to the robot. Fig. 4-4: Motion range of axis 1 with inclined installation Payloads, KR 8 R2010 Payloads Rated payload Maximum payload Rated mass moment of inertia Rated supplementary load, base frame Maximum supplementary load, base frame Rated supplementary load, rotating column 8 kg 9.7 kg 0.36 kgm² 0 kg 0 kg 0 kg 16/181 Spez KR CYBERTECH V4 Issued:

17 Maximum supplementary load, rotating column Rated supplementary load, link arm Maximum supplementary load, link arm Rated supplementary load, arm Maximum supplementary load, arm 20 kg 0 kg 15 kg 10 kg 15 kg Nominal distance to load center of gravity Lxy Lz 120 mm 150 mm Load center of gravity For all payloads, the load center of gravity refers to the distance from the face of the mounting flange on axis 6. Refer to the payload diagram for the nominal distance. Payload diagram Fig. 4-5: Load center of gravity NOTICE This loading curve corresponds to the maximum load capacity. Both values (payload and mass moment of inertia) must be checked in all cases. Exceeding this capacity will reduce the service life of the robot and overload the motors and the gears; in any such case KUKA Deutschland GmbH must be consulted beforehand. The values determined here are necessary for planning the robot application. For commissioning the robot, additional input data are required in accordance with the operating and programming instructions of the KUKA System Software. The mass inertia must be verified using KUKA.Load. It is imperative for the load data to be entered in the robot controller! Spez KR CYBERTECH V4 Issued: /181

18 Fig. 4-6: KR 8 R2010, payload diagram The KR 8 R2010 is designed for a rated payload of 8 kg in order to optimize the dynamic performance of the robot. With reduced load center distances, higher loads up to the maximum payload may be used. The specific load case must be verified using KUKA.Load. For further consultation, please contact KUKA Support. Mounting flange In-line wrist type ZH 8/12/16/20 Mounting flange Mounting flange (hole circle) Screw grade 12.9 Screw size Number of fastening threads 7 Clamping length Depth of engagement Locating element see drawing 50.0 mm M6 1.5 x nominal diameter min. 6 mm, max. 9 mm 6 H7 The mounting flange (>>> Fig. 4-7) is depicted with axes 4 and 6 in the zero position. The symbol X m indicates the position of the locating element (bushing) in the zero position. 18/181 Spez KR CYBERTECH V4 Issued:

19 Fig. 4-7: Mounting flange Flange loads Due to the motion of the payload (e.g. tool) mounted on the robot, forces and torques act on the mounting flange. These forces and torques depend on the motion profile as well as the mass, load center of gravity and mass moment of inertia of the payload. The specified values refer to nominal payloads at the nominal distance and do not include safety factors. It is imperative for the load data to be entered in the robot controller. The robot controller takes the payload into consideration during path planning. A reduced payload does not necessarily result in lower forces and torques. The values are guide values determined by means of trial and simulation and refer to the most heavily loaded machine in the robot family. The actual forces and torques may differ due to internal and external influences on the mounting flange or a different point of application. It is therefore advisable to determine the exact forces and torques where necessary on site under the real conditions of the actual robot application. The operating values may occur permanently in the normal motion profile. It is advisable to rate the tool for its fatigue strength. The EMERGENCY STOP values may arise in the event of an Emergency Stop situation of the robot. As these should only occur very rarely during the service life of the robot, a static strength verification is usually sufficient. Fig. 4-8: Flange loads Spez KR CYBERTECH V4 Issued: /181

20 Flange loads during operation F(a) 970 N F(r) 960 N M(k) 249 Nm M(g) 107 Nm Flange loads in the case of EMERGENCY STOP F(a) 1115 N F(r) 1280 N M(k) 326 Nm M(g) 164 Nm Axial force F(a), radial force F(r), tilting torque M(k), torque about mounting flange M(g) Supplementary load The robot can carry supplementary loads on the arm, link arm and rotating column. When mounting the supplementary loads, be careful to observe the maximum permissible total load. The dimensions and positions of the installation options can be seen in the following diagram. Fig. 4-9: Fastening the supplementary load, arm 1 Plane of rotation, axis 4 2 Mounting surface on arm 20/181 Spez KR CYBERTECH V4 Issued:

21 Fig. 4-10: Fastening the supplementary load, link arm/rotating column 1 Mounting surface on link arm 2 Mounting surface on rotating column, both sides Foundation loads, KR 8 R2010 Foundation loads The specified forces and moments already include the payload and the inertia force (weight) of the robot. Foundation loads for floor mounting position F(v normal) F(v max) F(h normal) F(h max) M(k normal) M(k max) M(r normal) M(r max) 4038 N 4434 N 2336 N 2988 N 3334 Nm 4177 Nm 1965 Nm 2361 Nm Foundation loads for ceiling mounting position F(v normal) F(v max) F(h normal) F(h max) M(k normal) M(k max) M(r normal) M(r max) 4104 N 4535 N 2272 N 2793 N 3642 Nm 4553 Nm 2017 Nm 2314 Nm Foundation loads for wall mounting position Spez KR CYBERTECH V4 Issued: /181

22 F(v normal) F(v max) F(h normal) F(h max) M(k normal) M(k max) M(r normal) M(r max) 4265 N 4661 N 1464 N 2268 N 4603 Nm 5124 Nm 1739 Nm 2368 Nm Vertical force F(v), horizontal force F(h), tilting torque M(k), torque about axis 1 M(r) Fig. 4-11: Foundation loads WARNING Normal loads and maximum loads for the foundations are specified in the table. The maximum loads must be referred to when dimensioning the foundations and must be adhered to for safety reasons. Failure to observe this can result in personal injury and damage to property. The normal loads are average expected foundation loads. The actual loads are dependent on the program and on the robot loads and may therefore be greater or less than the normal loads. The supplementary loads (A1 and A2) are not taken into consideration in the calculation of the mounting base load. These supplementary loads must be taken into consideration for F v. 22/181 Spez KR CYBERTECH V4 Issued:

23 4.3, KR 12 R Basic data, KR 12 R1810 Basic data Number of axes 6 Number of controlled axes 6 KR 12 R1810 Volume of working envelope 23.3 m³ Pose repeatability (ISO 9283) Weight Rated payload Maximum payload Maximum reach Protection rating (IEC 60529) Protection rating, in-line wrist (IEC 60529) Sound level Mounting position Footprint Hole pattern: mounting surface for kinematic system Permissible angle of inclination - ± 0.04 mm approx. 250 kg 12 kg 14.5 kg 1813 mm IP65 IP65 < 75 db (A) Floor; Ceiling; Wall; Desired angle mm x 370 mm S260 Default color Base frame: black (RAL 9005); Moving parts: KUKA orange 2567 Controller Transformation name KR C4 KR C4: KR12R1810 C4 Ambient conditions Humidity class (EN 60204) - Classification of environmental conditions (EN ) Ambient temperature 3K3 During operation 5 C to 55 C (278 K to 328 K) During storage/transportation -20 C to 60 C (253 K to 333 K) For operation at low temperatures, it may be necessary to warm up the robot. Spez KR CYBERTECH V4 Issued: /181

24 Connecting cables Cable designation Connector designation robot controller - robot Interface with robot Motor cable X20 - X30 Han-Yellock 60 Data cable X21 - X31 HAN Q12 Ground conductor / equipotential bonding 16 mm 2 (optional) M8 ring cable lug at both ends Cable lengths Standard Minimum bending radius 4 m, 7 m, 15 m, 25 m, 35 m, 50 m 5x D For detailed specifications of the connecting cables, see Description of the connecting cables Axis data, KR 12 R1810 Axis data Motion range A1 ±185 A2-185 / 65 A3-138 / 175 A4 ±350 A5 ±130 A6 ±350 Speed with rated payload A1 A2 A3 A4 A5 A6 200 /s 175 /s 190 /s 430 /s 430 /s 630 /s The direction of motion and the arrangement of the individual axes may be noted from the following diagram. 24/181 Spez KR CYBERTECH V4 Issued:

25 Fig. 4-12: Direction of rotation of robot axes Mastering positions Mastering position A1 27 A2 90 A3 90 A4 0 A5 0 A6 0 Working envelope The following diagrams show the shape and size of the working envelope for these variants of this product family. The reference point for the working envelope is the intersection of axes 4 and 5. Spez KR CYBERTECH V4 Issued: /181

26 Fig. 4-13: Working envelope, side view, KR 12 R1810 Fig. 4-14: Working envelope, top view, KR 12 R1810 Inclined installation The robot can installed anywhere from a 0 position (floor) to a 180 position (ceiling). The following figure shows the possible limitation of the motion range of axis 1, as a function of the angle of inclination of the robot. The inclination angles for the robot must be entered correctly into the controller if the robot is not operated in the floor-mounted position. Configuration of the angles is possible via WorkVisual. The inclination angles for an unchanged main working direction of the robot: Floor: A:0, B:0, C:0 26/181 Spez KR CYBERTECH V4 Issued:

27 Wall: A:0, B:90, C:0 Ceiling: A:0, B:0, C:180 CAUTION The inclined installation angles must be individually checked and entered. An incorrectly entered inclined installation angle can lead to unforeseen motion and/or to an overload and, potentially, damage to the robot. Fig. 4-15: Motion range of axis 1 with inclined installation Payloads, KR 12 R1810 Payloads Rated payload Maximum payload Rated mass moment of inertia Rated supplementary load, base frame Maximum supplementary load, base frame Rated supplementary load, rotating column Maximum supplementary load, rotating column 12 kg 14.5 kg 0.36 kgm² 0 kg 0 kg 0 kg 20 kg Spez KR CYBERTECH V4 Issued: /181

28 Rated supplementary load, link arm Maximum supplementary load, link arm Rated supplementary load, arm Maximum supplementary load, arm 0 kg 15 kg 10 kg 15 kg Nominal distance to load center of gravity Lxy Lz 120 mm 150 mm Load center of gravity For all payloads, the load center of gravity refers to the distance from the face of the mounting flange on axis 6. Refer to the payload diagram for the nominal distance. Payload diagram Fig. 4-16: Load center of gravity NOTICE This loading curve corresponds to the maximum load capacity. Both values (payload and mass moment of inertia) must be checked in all cases. Exceeding this capacity will reduce the service life of the robot and overload the motors and the gears; in any such case KUKA Deutschland GmbH must be consulted beforehand. The values determined here are necessary for planning the robot application. For commissioning the robot, additional input data are required in accordance with the operating and programming instructions of the KUKA System Software. The mass inertia must be verified using KUKA.Load. It is imperative for the load data to be entered in the robot controller! 28/181 Spez KR CYBERTECH V4 Issued:

29 Fig. 4-17: KR 12 R1810, payload diagram The KR 12 R1810 is designed for a rated payload of 12 kg in order to optimize the dynamic performance of the robot. With reduced load center distances, higher loads up to the maximum payload may be used. The specific load case must be verified using KUKA.Load. For further consultation, please contact KUKA Support. Mounting flange In-line wrist type ZH 8/12/16/20 Mounting flange Mounting flange (hole circle) Screw grade 12.9 Screw size Number of fastening threads 7 Clamping length Depth of engagement Locating element see drawing 50.0 mm M6 1.5 x nominal diameter min. 6 mm, max. 9 mm 6 H7 The mounting flange (>>> Fig. 4-18) is depicted with axes 4 and 6 in the zero position. The symbol X m indicates the position of the locating element (bushing) in the zero position. Spez KR CYBERTECH V4 Issued: /181

30 Fig. 4-18: Mounting flange Flange loads Due to the motion of the payload (e.g. tool) mounted on the robot, forces and torques act on the mounting flange. These forces and torques depend on the motion profile as well as the mass, load center of gravity and mass moment of inertia of the payload. The specified values refer to nominal payloads at the nominal distance and do not include safety factors. It is imperative for the load data to be entered in the robot controller. The robot controller takes the payload into consideration during path planning. A reduced payload does not necessarily result in lower forces and torques. The values are guide values determined by means of trial and simulation and refer to the most heavily loaded machine in the robot family. The actual forces and torques may differ due to internal and external influences on the mounting flange or a different point of application. It is therefore advisable to determine the exact forces and torques where necessary on site under the real conditions of the actual robot application. The operating values may occur permanently in the normal motion profile. It is advisable to rate the tool for its fatigue strength. The EMERGENCY STOP values may arise in the event of an Emergency Stop situation of the robot. As these should only occur very rarely during the service life of the robot, a static strength verification is usually sufficient. Fig. 4-19: Flange loads 30/181 Spez KR CYBERTECH V4 Issued:

31 Flange loads during operation F(a) 970 N F(r) 960 N M(k) 249 Nm M(g) 107 Nm Flange loads in the case of EMERGENCY STOP F(a) 1115 N F(r) 1280 N M(k) 326 Nm M(g) 164 Nm Axial force F(a), radial force F(r), tilting torque M(k), torque about mounting flange M(g) Supplementary load The robot can carry supplementary loads on the arm, link arm and rotating column. When mounting the supplementary loads, be careful to observe the maximum permissible total load. The dimensions and positions of the installation options can be seen in the following diagram. Fig. 4-20: Fastening the supplementary load, arm 1 Plane of rotation, axis 4 2 Mounting surface on arm Spez KR CYBERTECH V4 Issued: /181

32 Fig. 4-21: Fastening the supplementary load, link arm/rotating column 1 Mounting surface on link arm 2 Mounting surface on rotating column, both sides Foundation loads, KR 12 R1810 Foundation loads The specified forces and moments already include the payload and the inertia force (weight) of the robot. Foundation loads for floor mounting position F(v normal) F(v max) F(h normal) F(h max) M(k normal) M(k max) M(r normal) M(r max) 4038 N 4434 N 2336 N 2988 N 3334 Nm 4177 Nm 1965 Nm 2361 Nm Foundation loads for ceiling mounting position F(v normal) F(v max) F(h normal) F(h max) M(k normal) M(k max) M(r normal) M(r max) 4104 N 4535 N 2272 N 2793 N 3642 Nm 4553 Nm 2017 Nm 2314 Nm Foundation loads for wall mounting position 32/181 Spez KR CYBERTECH V4 Issued:

33 F(v normal) F(v max) F(h normal) F(h max) M(k normal) M(k max) M(r normal) M(r max) 4265 N 4661 N 1464 N 2268 N 4603 Nm 5124 Nm 1739 Nm 2368 Nm Vertical force F(v), horizontal force F(h), tilting torque M(k), torque about axis 1 M(r) Fig. 4-22: Foundation loads WARNING Normal loads and maximum loads for the foundations are specified in the table. The maximum loads must be referred to when dimensioning the foundations and must be adhered to for safety reasons. Failure to observe this can result in personal injury and damage to property. The normal loads are average expected foundation loads. The actual loads are dependent on the program and on the robot loads and may therefore be greater or less than the normal loads. The supplementary loads (A1 and A2) are not taken into consideration in the calculation of the mounting base load. These supplementary loads must be taken into consideration for F v. Spez KR CYBERTECH V4 Issued: /181

34 4.4, KR 16 R Basic data, KR 16 R1610 Basic data Number of axes 6 Number of controlled axes 6 KR 16 R1610 Volume of working envelope m³ Pose repeatability (ISO 9283) Weight Rated payload Maximum payload Maximum reach Protection rating (IEC 60529) Protection rating, in-line wrist (IEC 60529) Sound level Mounting position Footprint Hole pattern: mounting surface for kinematic system Permissible angle of inclination - ± 0.04 mm approx. 245 kg 16 kg 20 kg 1612 mm IP65 IP65 < 75 db (A) Floor; Ceiling; Wall; Desired angle mm x 370 mm S260 Default color Base frame: black (RAL 9005); Moving parts: KUKA orange 2567 Controller Transformation name KR C4 KR C4: KR16R1610 C4 Ambient conditions Humidity class (EN 60204) - Classification of environmental conditions (EN ) Ambient temperature 3K3 During operation 5 C to 55 C (278 K to 328 K) During storage/transportation -20 C to 60 C (253 K to 333 K) For operation at low temperatures, it may be necessary to warm up the robot. 34/181 Spez KR CYBERTECH V4 Issued:

35 Connecting cables Cable designation Connector designation robot controller - robot Interface with robot Motor cable X20 - X30 Han-Yellock 60 Data cable X21 - X31 HAN Q12 Ground conductor / equipotential bonding 16 mm 2 (optional) M8 ring cable lug at both ends Cable lengths Standard Minimum bending radius 4 m, 7 m, 15 m, 25 m, 35 m, 50 m 5x D For detailed specifications of the connecting cables, see Description of the connecting cables Axis data, KR 16 R1610 Axis data Motion range A1 ±185 A2-185 / 65 A3-138 / 175 A4 ±350 A5 ±130 A6 ±350 Speed with rated payload A1 A2 A3 A4 A5 A6 200 /s 175 /s 190 /s 430 /s 430 /s 630 /s The direction of motion and the arrangement of the individual axes may be noted from the following diagram. Spez KR CYBERTECH V4 Issued: /181

36 Fig. 4-23: Direction of rotation of robot axes Mastering positions Mastering position A1 27 A2 90 A3 90 A4 0 A5 0 A6 0 Working envelope The following diagrams show the shape and size of the working envelope for these variants of this product family. The reference point for the working envelope is the intersection of axes 4 and 5. Fig. 4-24: Working envelope, side view, KR 16 R /181 Spez KR CYBERTECH V4 Issued:

37 Fig. 4-25: Working envelope, top view, KR 16 R1610 Inclined installation The robot can installed anywhere from a 0 position (floor) to a 180 position (ceiling). The following figure shows the possible limitation of the motion range of axis 1, as a function of the angle of inclination of the robot. The inclination angles for the robot must be entered correctly into the controller if the robot is not operated in the floor-mounted position. Configuration of the angles is possible via WorkVisual. The inclination angles for an unchanged main working direction of the robot: Floor: A:0, B:0, C:0 Wall: A:0, B:90, C:0 Ceiling: A:0, B:0, C:180 CAUTION The inclined installation angles must be individually checked and entered. An incorrectly entered inclined installation angle can lead to unforeseen motion and/or to an overload and, potentially, damage to the robot. Spez KR CYBERTECH V4 Issued: /181

38 Fig. 4-26: Motion range of axis 1 with inclined installation Payloads, KR 16 R1610 Payloads Rated payload Maximum payload Rated mass moment of inertia Rated supplementary load, base frame Maximum supplementary load, base frame Rated supplementary load, rotating column Maximum supplementary load, rotating column Rated supplementary load, link arm Maximum supplementary load, link arm Rated supplementary load, arm Maximum supplementary load, arm 16 kg 20 kg 0.36 kgm² 0 kg 0 kg 0 kg 20 kg 0 kg 15 kg 10 kg 15 kg 38/181 Spez KR CYBERTECH V4 Issued:

39 Nominal distance to load center of gravity Lxy 120 mm Lz 150 mm Load center of gravity For all payloads, the load center of gravity refers to the distance from the face of the mounting flange on axis 6. Refer to the payload diagram for the nominal distance. Fig. 4-27: Load center of gravity Payload diagram NOTICE This loading curve corresponds to the maximum load capacity. Both values (payload and mass moment of inertia) must be checked in all cases. Exceeding this capacity will reduce the service life of the robot and overload the motors and the gears; in any such case KUKA Deutschland GmbH must be consulted beforehand. The values determined here are necessary for planning the robot application. For commissioning the robot, additional input data are required in accordance with the operating and programming instructions of the KUKA System Software. The mass inertia must be verified using KUKA.Load. It is imperative for the load data to be entered in the robot controller! Spez KR CYBERTECH V4 Issued: /181

40 Fig. 4-28: KR 16 R1610, payload diagram The KR 16 R1610 is designed for a rated payload of 16 kg in order to optimize the dynamic performance of the robot. With reduced load center distances, higher loads up to the maximum payload may be used. The specific load case must be verified using KUKA.Load. For further consultation, please contact KUKA Support. Mounting flange In-line wrist type ZH 16/22 Mounting flange Mounting flange (hole circle) Screw grade 12.9 Screw size Number of fastening threads 7 Clamping length Depth of engagement Locating element see drawing 50.0 mm M6 1.5 x nominal diameter min. 6 mm, max. 9 mm 6 H7 The mounting flange (>>> Fig. 4-29) is depicted with axes 4 and 6 in the zero position. The symbol X m indicates the position of the locating element (bushing) in the zero position. 40/181 Spez KR CYBERTECH V4 Issued:

41 Fig. 4-29: Mounting flange Flange loads Due to the motion of the payload (e.g. tool) mounted on the robot, forces and torques act on the mounting flange. These forces and torques depend on the motion profile as well as the mass, load center of gravity and mass moment of inertia of the payload. The specified values refer to nominal payloads at the nominal distance and do not include safety factors. It is imperative for the load data to be entered in the robot controller. The robot controller takes the payload into consideration during path planning. A reduced payload does not necessarily result in lower forces and torques. The values are guide values determined by means of trial and simulation and refer to the most heavily loaded machine in the robot family. The actual forces and torques may differ due to internal and external influences on the mounting flange or a different point of application. It is therefore advisable to determine the exact forces and torques where necessary on site under the real conditions of the actual robot application. The operating values may occur permanently in the normal motion profile. It is advisable to rate the tool for its fatigue strength. The EMERGENCY STOP values may arise in the event of an Emergency Stop situation of the robot. As these should only occur very rarely during the service life of the robot, a static strength verification is usually sufficient. Fig. 4-30: Flange loads Spez KR CYBERTECH V4 Issued: /181

42 Flange loads during operation F(a) 970 N F(r) 960 N M(k) 249 Nm M(g) 107 Nm Flange loads in the case of EMERGENCY STOP F(a) 1115 N F(r) 1280 N M(k) 326 Nm M(g) 164 Nm Axial force F(a), radial force F(r), tilting torque M(k), torque about mounting flange M(g) Supplementary load The robot can carry supplementary loads on the arm, link arm and rotating column. When mounting the supplementary loads, be careful to observe the maximum permissible total load. The dimensions and positions of the installation options can be seen in the following diagram. Fig. 4-31: Fastening the supplementary load, arm 1 Plane of rotation, axis 4 2 Mounting surface on arm 42/181 Spez KR CYBERTECH V4 Issued:

43 Fig. 4-32: Fastening the supplementary load, link arm/rotating column 1 Mounting surface on link arm 2 Mounting surface on rotating column, both sides Foundation loads, KR 16 R1610 Foundation loads The specified forces and moments already include the payload and the inertia force (weight) of the robot. Foundation loads for floor mounting position F(v normal) F(v max) F(h normal) F(h max) M(k normal) M(k max) M(r normal) M(r max) 4038 N 4434 N 2336 N 2988 N 3334 Nm 4177 Nm 1965 Nm 2361 Nm Foundation loads for ceiling mounting position F(v normal) F(v max) F(h normal) F(h max) M(k normal) M(k max) M(r normal) M(r max) 4104 N 4535 N 2272 N 2793 N 3642 Nm 4553 Nm 2017 Nm 2314 Nm Foundation loads for wall mounting position Spez KR CYBERTECH V4 Issued: /181

44 F(v normal) F(v max) F(h normal) F(h max) M(k normal) M(k max) M(r normal) M(r max) 4265 N 4661 N 1464 N 2268 N 4603 Nm 5124 Nm 1739 Nm 2368 Nm Vertical force F(v), horizontal force F(h), tilting torque M(k), torque about axis 1 M(r) Fig. 4-33: Foundation loads WARNING Normal loads and maximum loads for the foundations are specified in the table. The maximum loads must be referred to when dimensioning the foundations and must be adhered to for safety reasons. Failure to observe this can result in personal injury and damage to property. The normal loads are average expected foundation loads. The actual loads are dependent on the program and on the robot loads and may therefore be greater or less than the normal loads. The supplementary loads (A1 and A2) are not taken into consideration in the calculation of the mounting base load. These supplementary loads must be taken into consideration for F v. 44/181 Spez KR CYBERTECH V4 Issued:

45 4.5, KR 16 R Basic data, KR 16 R2010 Basic data Number of axes 6 Number of controlled axes 6 KR 16 R2010 Volume of working envelope 32.5 m³ Pose repeatability (ISO 9283) Weight Rated payload Maximum payload Maximum reach Protection rating (IEC 60529) Protection rating, in-line wrist (IEC 60529) Sound level Mounting position Footprint Hole pattern: mounting surface for kinematic system Permissible angle of inclination - ± 0.04 mm approx. 255 kg 16 kg 19.2 kg 2013 mm IP65 IP65 < 75 db (A) Floor; Ceiling; Wall; Desired angle mm x 370 mm S260 Default color Base frame: black (RAL 9005); Moving parts: KUKA orange 2567 Controller Transformation name KR C4 KR C4: KR16R2010 C4 Ambient conditions Humidity class (EN 60204) - Classification of environmental conditions (EN ) Ambient temperature 3K3 During operation 5 C to 55 C (278 K to 328 K) During storage/transportation -20 C to 60 C (253 K to 333 K) For operation at low temperatures, it may be necessary to warm up the robot. Spez KR CYBERTECH V4 Issued: /181

46 Connecting cables Cable designation Connector designation robot controller - robot Interface with robot Motor cable X20 - X30 Han-Yellock 60 Data cable X21 - X31 HAN Q12 Ground conductor / equipotential bonding 16 mm 2 (optional) M8 ring cable lug at both ends Cable lengths Standard Minimum bending radius 4 m, 7 m, 15 m, 25 m, 35 m, 50 m 5x D For detailed specifications of the connecting cables, see Description of the connecting cables Axis data, KR 16 R2010 Axis data Motion range A1 ±185 A2-185 / 65 A3-138 / 175 A4 ±350 A5 ±130 A6 ±350 Speed with rated payload A1 A2 A3 A4 A5 A6 200 /s 175 /s 190 /s 430 /s 430 /s 630 /s The direction of motion and the arrangement of the individual axes may be noted from the following diagram. 46/181 Spez KR CYBERTECH V4 Issued:

47 Fig. 4-34: Direction of rotation of robot axes Mastering positions Mastering position A1 27 A2 90 A3 90 A4 0 A5 0 A6 0 Working envelope The following diagrams show the shape and size of the working envelope for these variants of this product family. The reference point for the working envelope is the intersection of axes 4 and 5. Spez KR CYBERTECH V4 Issued: /181

48 Fig. 4-35: Working envelope, side view, KR 16 R2010 Fig. 4-36: Working envelope, top view, KR 16 R2010 Inclined installation The robot can installed anywhere from a 0 position (floor) to a 180 position (ceiling). The following figure shows the possible limitation of the motion range of axis 1, as a function of the angle of inclination of the robot. The inclination angles for the robot must be entered correctly into the controller if the robot is not operated in the floor-mounted position. Configuration of the angles is possible via WorkVisual. The inclination angles for an unchanged main working direction of the robot: 48/181 Spez KR CYBERTECH V4 Issued:

49 Floor: A:0, B:0, C:0 Wall: A:0, B:90, C:0 Ceiling: A:0, B:0, C:180 CAUTION The inclined installation angles must be individually checked and entered. An incorrectly entered inclined installation angle can lead to unforeseen motion and/or to an overload and, potentially, damage to the robot. Fig. 4-37: Motion range of axis 1 with inclined installation Payloads, KR 16 R2010 Payloads Rated payload Maximum payload Rated mass moment of inertia Rated supplementary load, base frame Maximum supplementary load, base frame Rated supplementary load, rotating column 16 kg 19.2 kg 0.36 kgm² 0 kg 0 kg 0 kg Spez KR CYBERTECH V4 Issued: /181

50 Maximum supplementary load, rotating column Rated supplementary load, link arm Maximum supplementary load, link arm Rated supplementary load, arm Maximum supplementary load, arm 20 kg 0 kg 15 kg 10 kg 15 kg Nominal distance to load center of gravity Lxy Lz 120 mm 150 mm Load center of gravity For all payloads, the load center of gravity refers to the distance from the face of the mounting flange on axis 6. Refer to the payload diagram for the nominal distance. Payload diagram Fig. 4-38: Load center of gravity NOTICE This loading curve corresponds to the maximum load capacity. Both values (payload and mass moment of inertia) must be checked in all cases. Exceeding this capacity will reduce the service life of the robot and overload the motors and the gears; in any such case KUKA Deutschland GmbH must be consulted beforehand. The values determined here are necessary for planning the robot application. For commissioning the robot, additional input data are required in accordance with the operating and programming instructions of the KUKA System Software. The mass inertia must be verified using KUKA.Load. It is imperative for the load data to be entered in the robot controller! 50/181 Spez KR CYBERTECH V4 Issued:

51 Fig. 4-39: KR 16 R2010, payload diagram The KR 16 R2010 is designed for a rated payload of 16 kg in order to optimize the dynamic performance of the robot. With reduced load center distances, higher loads up to the maximum payload may be used. The specific load case must be verified using KUKA.Load. For further consultation, please contact KUKA Support. Mounting flange In-line wrist type ZH 8/12/16/20 Mounting flange Mounting flange (hole circle) Screw grade 12.9 Screw size Number of fastening threads 7 Clamping length Depth of engagement Locating element see drawing 50.0 mm M6 1.5 x nominal diameter min. 6 mm, max. 9 mm 6 H7 The mounting flange (>>> Fig. 4-40) is depicted with axes 4 and 6 in the zero position. The symbol X m indicates the position of the locating element (bushing) in the zero position. Spez KR CYBERTECH V4 Issued: /181

52 Fig. 4-40: Mounting flange Flange loads Due to the motion of the payload (e.g. tool) mounted on the robot, forces and torques act on the mounting flange. These forces and torques depend on the motion profile as well as the mass, load center of gravity and mass moment of inertia of the payload. The specified values refer to nominal payloads at the nominal distance and do not include safety factors. It is imperative for the load data to be entered in the robot controller. The robot controller takes the payload into consideration during path planning. A reduced payload does not necessarily result in lower forces and torques. The values are guide values determined by means of trial and simulation and refer to the most heavily loaded machine in the robot family. The actual forces and torques may differ due to internal and external influences on the mounting flange or a different point of application. It is therefore advisable to determine the exact forces and torques where necessary on site under the real conditions of the actual robot application. The operating values may occur permanently in the normal motion profile. It is advisable to rate the tool for its fatigue strength. The EMERGENCY STOP values may arise in the event of an Emergency Stop situation of the robot. As these should only occur very rarely during the service life of the robot, a static strength verification is usually sufficient. Fig. 4-41: Flange loads 52/181 Spez KR CYBERTECH V4 Issued:

53 Flange loads during operation F(a) 970 N F(r) 960 N M(k) 249 Nm M(g) 107 Nm Flange loads in the case of EMERGENCY STOP F(a) 1115 N F(r) 1280 N M(k) 326 Nm M(g) 164 Nm Axial force F(a), radial force F(r), tilting torque M(k), torque about mounting flange M(g) Supplementary load The robot can carry supplementary loads on the arm, link arm and rotating column. When mounting the supplementary loads, be careful to observe the maximum permissible total load. The dimensions and positions of the installation options can be seen in the following diagram. Fig. 4-42: Fastening the supplementary load, arm 1 Plane of rotation, axis 4 2 Mounting surface on arm Spez KR CYBERTECH V4 Issued: /181

54 Fig. 4-43: Fastening the supplementary load, link arm/rotating column 1 Mounting surface on link arm 2 Mounting surface on rotating column, both sides Foundation loads, KR 16 R2010 Foundation loads The specified forces and moments already include the payload and the inertia force (weight) of the robot. Foundation loads for floor mounting position F(v normal) F(v max) F(h normal) F(h max) M(k normal) M(k max) M(r normal) M(r max) 4038 N 4434 N 2336 N 2988 N 3334 Nm 4177 Nm 1965 Nm 2361 Nm Foundation loads for ceiling mounting position F(v normal) F(v max) F(h normal) F(h max) M(k normal) M(k max) M(r normal) M(r max) 4104 N 4535 N 2272 N 2793 N 3642 Nm 4553 Nm 2017 Nm 2314 Nm Foundation loads for wall mounting position 54/181 Spez KR CYBERTECH V4 Issued:

55 F(v normal) F(v max) F(h normal) F(h max) M(k normal) M(k max) M(r normal) M(r max) 4265 N 4661 N 1464 N 2268 N 4603 Nm 5124 Nm 1739 Nm 2368 Nm Vertical force F(v), horizontal force F(h), tilting torque M(k), torque about axis 1 M(r) Fig. 4-44: Foundation loads WARNING Normal loads and maximum loads for the foundations are specified in the table. The maximum loads must be referred to when dimensioning the foundations and must be adhered to for safety reasons. Failure to observe this can result in personal injury and damage to property. The normal loads are average expected foundation loads. The actual loads are dependent on the program and on the robot loads and may therefore be greater or less than the normal loads. The supplementary loads (A1 and A2) are not taken into consideration in the calculation of the mounting base load. These supplementary loads must be taken into consideration for F v. Spez KR CYBERTECH V4 Issued: /181

56 4.6, KR 20 R Basic data, KR 20 R1810 Basic data Number of axes 6 Number of controlled axes 6 KR 20 R1810 Volume of working envelope 23.3 m³ Pose repeatability (ISO 9283) Weight Rated payload Maximum payload Maximum reach Protection rating (IEC 60529) Protection rating, in-line wrist (IEC 60529) Sound level Mounting position Footprint Hole pattern: mounting surface for kinematic system Permissible angle of inclination - ± 0.04 mm approx. 250 kg 20 kg 23 kg 1813 mm IP65 IP65 < 75 db (A) Floor; Ceiling; Wall; Desired angle mm x 370 mm S260 Default color Base frame: black (RAL 9005); Moving parts: KUKA orange 2567 Controller Transformation name KR C4 KR C4: KR20R1810 C4 Ambient conditions Humidity class (EN 60204) - Classification of environmental conditions (EN ) Ambient temperature 3K3 During operation 5 C to 55 C (278 K to 328 K) During storage/transportation -20 C to 60 C (253 K to 333 K) For operation at low temperatures, it may be necessary to warm up the robot. 56/181 Spez KR CYBERTECH V4 Issued:

57 Connecting cables Cable designation Connector designation robot controller - robot Interface with robot Motor cable X20 - X30 Han-Yellock 60 Data cable X21 - X31 HAN Q12 Ground conductor / equipotential bonding 16 mm 2 (optional) M8 ring cable lug at both ends Cable lengths Standard Minimum bending radius 4 m, 7 m, 15 m, 25 m, 35 m, 50 m 5x D For detailed specifications of the connecting cables, see Description of the connecting cables Axis data, KR 20 R1810 Axis data Motion range A1 ±185 A2-185 / 65 A3-138 / 175 A4 ±350 A5 ±130 A6 ±350 Speed with rated payload A1 A2 A3 A4 A5 A6 200 /s 175 /s 190 /s 430 /s 430 /s 630 /s The direction of motion and the arrangement of the individual axes may be noted from the following diagram. Spez KR CYBERTECH V4 Issued: /181

58 Fig. 4-45: Direction of rotation of robot axes Mastering positions Mastering position A1 27 A2 90 A3 90 A4 0 A5 0 A6 0 Working envelope The following diagrams show the shape and size of the working envelope for these variants of this product family. The reference point for the working envelope is the intersection of axes 4 and 5. 58/181 Spez KR CYBERTECH V4 Issued:

59 Fig. 4-46: Working envelope, side view, KR 20 R1810 Fig. 4-47: Working envelope, top view, KR 20 R1810 Inclined installation The robot can installed anywhere from a 0 position (floor) to a 180 position (ceiling). The following figure shows the possible limitation of the motion range of axis 1, as a function of the angle of inclination of the robot. The inclination angles for the robot must be entered correctly into the controller if the robot is not operated in the floor-mounted position. Configuration of the angles is possible via WorkVisual. The inclination angles for an unchanged main working direction of the robot: Floor: A:0, B:0, C:0 Spez KR CYBERTECH V4 Issued: /181

60 Wall: A:0, B:90, C:0 Ceiling: A:0, B:0, C:180 CAUTION The inclined installation angles must be individually checked and entered. An incorrectly entered inclined installation angle can lead to unforeseen motion and/or to an overload and, potentially, damage to the robot. Fig. 4-48: Motion range of axis 1 with inclined installation Payloads, KR 20 R1810 Payloads Rated payload Maximum payload Rated mass moment of inertia Rated supplementary load, base frame Maximum supplementary load, base frame Rated supplementary load, rotating column Maximum supplementary load, rotating column 20 kg 23 kg 0.36 kgm² 0 kg 0 kg 0 kg 20 kg 60/181 Spez KR CYBERTECH V4 Issued:

61 Rated supplementary load, link arm Maximum supplementary load, link arm Rated supplementary load, arm Maximum supplementary load, arm 0 kg 15 kg 10 kg 15 kg Nominal distance to load center of gravity Lxy Lz 120 mm 150 mm Load center of gravity For all payloads, the load center of gravity refers to the distance from the face of the mounting flange on axis 6. Refer to the payload diagram for the nominal distance. Payload diagram Fig. 4-49: Load center of gravity NOTICE This loading curve corresponds to the maximum load capacity. Both values (payload and mass moment of inertia) must be checked in all cases. Exceeding this capacity will reduce the service life of the robot and overload the motors and the gears; in any such case KUKA Deutschland GmbH must be consulted beforehand. The values determined here are necessary for planning the robot application. For commissioning the robot, additional input data are required in accordance with the operating and programming instructions of the KUKA System Software. The mass inertia must be verified using KUKA.Load. It is imperative for the load data to be entered in the robot controller! Spez KR CYBERTECH V4 Issued: /181

62 Fig. 4-50: KR 20 R1810, payload diagram The KR 20 R1810 is designed for a rated payload of 20 kg in order to optimize the dynamic performance of the robot. With reduced load center distances, higher loads up to the maximum payload may be used. The specific load case must be verified using KUKA.Load. For further consultation, please contact KUKA Support. Mounting flange In-line wrist type ZH 8/12/16/20 Mounting flange Mounting flange (hole circle) Screw grade 12.9 Screw size Number of fastening threads 7 Clamping length Depth of engagement Locating element see drawing 50.0 mm M6 1.5 x nominal diameter min. 6 mm, max. 9 mm 6 H7 The mounting flange (>>> Fig. 4-51) is depicted with axes 4 and 6 in the zero position. The symbol X m indicates the position of the locating element (bushing) in the zero position. 62/181 Spez KR CYBERTECH V4 Issued:

63 Fig. 4-51: Mounting flange Flange loads Due to the motion of the payload (e.g. tool) mounted on the robot, forces and torques act on the mounting flange. These forces and torques depend on the motion profile as well as the mass, load center of gravity and mass moment of inertia of the payload. The specified values refer to nominal payloads at the nominal distance and do not include safety factors. It is imperative for the load data to be entered in the robot controller. The robot controller takes the payload into consideration during path planning. A reduced payload does not necessarily result in lower forces and torques. The values are guide values determined by means of trial and simulation and refer to the most heavily loaded machine in the robot family. The actual forces and torques may differ due to internal and external influences on the mounting flange or a different point of application. It is therefore advisable to determine the exact forces and torques where necessary on site under the real conditions of the actual robot application. The operating values may occur permanently in the normal motion profile. It is advisable to rate the tool for its fatigue strength. The EMERGENCY STOP values may arise in the event of an Emergency Stop situation of the robot. As these should only occur very rarely during the service life of the robot, a static strength verification is usually sufficient. Fig. 4-52: Flange loads Spez KR CYBERTECH V4 Issued: /181

64 Flange loads during operation F(a) 970 N F(r) 960 N M(k) 249 Nm M(g) 107 Nm Flange loads in the case of EMERGENCY STOP F(a) 1115 N F(r) 1280 N M(k) 326 Nm M(g) 164 Nm Axial force F(a), radial force F(r), tilting torque M(k), torque about mounting flange M(g) Supplementary load The robot can carry supplementary loads on the arm, link arm and rotating column. When mounting the supplementary loads, be careful to observe the maximum permissible total load. The dimensions and positions of the installation options can be seen in the following diagram. Fig. 4-53: Fastening the supplementary load, arm 1 Plane of rotation, axis 4 2 Mounting surface on arm 64/181 Spez KR CYBERTECH V4 Issued:

65 Fig. 4-54: Fastening the supplementary load, link arm/rotating column 1 Mounting surface on link arm 2 Mounting surface on rotating column, both sides Foundation loads, KR 20 R1810 Foundation loads The specified forces and moments already include the payload and the inertia force (weight) of the robot. Foundation loads for floor mounting position F(v normal) F(v max) F(h normal) F(h max) M(k normal) M(k max) M(r normal) M(r max) 4038 N 4434 N 2336 N 2988 N 3334 Nm 4177 Nm 1965 Nm 2361 Nm Foundation loads for ceiling mounting position F(v normal) F(v max) F(h normal) F(h max) M(k normal) M(k max) M(r normal) M(r max) 4104 N 4535 N 2272 N 2793 N 3642 Nm 4553 Nm 2017 Nm 2314 Nm Foundation loads for wall mounting position Spez KR CYBERTECH V4 Issued: /181

66 F(v normal) F(v max) F(h normal) F(h max) M(k normal) M(k max) M(r normal) M(r max) 4265 N 4661 N 1464 N 2268 N 4603 Nm 5124 Nm 1739 Nm 2368 Nm Vertical force F(v), horizontal force F(h), tilting torque M(k), torque about axis 1 M(r) Fig. 4-55: Foundation loads WARNING Normal loads and maximum loads for the foundations are specified in the table. The maximum loads must be referred to when dimensioning the foundations and must be adhered to for safety reasons. Failure to observe this can result in personal injury and damage to property. The normal loads are average expected foundation loads. The actual loads are dependent on the program and on the robot loads and may therefore be greater or less than the normal loads. The supplementary loads (A1 and A2) are not taken into consideration in the calculation of the mounting base load. These supplementary loads must be taken into consideration for F v. 66/181 Spez KR CYBERTECH V4 Issued:

67 4.7, KR 20 R1810 F Basic data, KR 20 R1810 F Basic data Number of axes 6 Number of controlled axes 6 Volume of working envelope 23.3 m³ Pose repeatability (ISO 9283) Weight Rated payload Maximum payload Maximum reach Protection rating (IEC 60529) Protection rating, in-line wrist (IEC 60529) Sound level Mounting position Footprint Hole pattern: mounting surface for kinematic system Permissible angle of inclination - KR 20 R1810 F ± 0.04 mm approx. 250 kg 20 kg 23 kg 1813 mm IP65 IP67 < 75 db (A) Floor; Ceiling; Wall; Desired angle mm x 370 mm S260 Default color Base frame: black (RAL 9005); Moving parts: KUKA orange 2567 Controller Transformation name KR C4 KR C4: #KR20R1810 C4 Foundry robots Overpressure in the arm Compressed air Compressed air supply line Air consumption 0.1 m 3 /h Air line connection Input pressure Pressure regulator Manometer range Thermal loading 0.01 MPa (0.1 bar) ±10% Free of oil and water Class 4 in accordance with ISO Air line in the cable set Push-in fitting for hose, 6 mm MPa (1-12 bar) MPa ( bar) MPa ( bar) 10 s/min at 353 K (180 C) Spez KR CYBERTECH V4 Issued: /181

68 Resistance Special paint finish on wrist Special paint finish on the robot Other ambient conditions Increased resistance to dust, lubricants, coolants and water vapor. Heat-resistant and heat-reflecting silver paint finish on the in-line wrist. Special paint finish on the entire robot, and an additional protective clear coat. KUKA Deutschland GmbH must be consulted if the robot is to be used under other ambient conditions. Ambient conditions Humidity class (EN 60204) - Classification of environmental conditions (EN ) Ambient temperature 3K3 During operation 5 C to 55 C (278 K to 328 K) During storage/transportation -20 C to 60 C (253 K to 333 K) For operation at low temperatures, it may be necessary to warm up the robot. Connecting cables Cable designation Connector designation robot controller - robot Interface with robot Motor cable X20 - X30 Han-Yellock 60 Data cable X21 - X31 HAN Q12 Ground conductor / equipotential bonding 16 mm 2 (optional) M8 ring cable lug at both ends Cable lengths Standard Minimum bending radius 4 m, 7 m, 15 m, 25 m, 35 m, 50 m 5x D For detailed specifications of the connecting cables, see Description of the connecting cables Axis data, KR 20 R1810 F Axis data Motion range A1 ±185 A2-185 / 65 A3-138 / 175 A4 ±350 68/181 Spez KR CYBERTECH V4 Issued:

69 A5 ±130 A6 ±350 Speed with rated payload A1 200 /s A2 175 /s A3 190 /s A4 430 /s A5 430 /s A6 630 /s The direction of motion and the arrangement of the individual axes may be noted from the following diagram. Fig. 4-56: Direction of rotation of robot axes Mastering positions Mastering position A1 27 A2 90 A3 90 A4 0 A5 0 A6 0 Working envelope The following diagrams show the shape and size of the working envelope for these variants of this product family. The reference point for the working envelope is the intersection of axes 4 and 5. Spez KR CYBERTECH V4 Issued: /181

70 Fig. 4-57: Working envelope, side view, KR 20 R1810 F Fig. 4-58: Working envelope, top view, KR 20 R1810 F Inclined installation The robot can installed anywhere from a 0 position (floor) to a 180 position (ceiling). The following figure shows the possible limitation of the motion range of axis 1, as a function of the angle of inclination of the robot. The inclination angles for the robot must be entered correctly into the controller if the robot is not operated in the floor-mounted position. Configuration of the angles is possible via WorkVisual. The inclination angles for an unchanged main working direction of the robot: Floor: A:0, B:0, C:0 70/181 Spez KR CYBERTECH V4 Issued:

71 Wall: A:0, B:90, C:0 Ceiling: A:0, B:0, C:180 CAUTION The inclined installation angles must be individually checked and entered. An incorrectly entered inclined installation angle can lead to unforeseen motion and/or to an overload and, potentially, damage to the robot. Fig. 4-59: Motion range of axis 1 with inclined installation Payloads, KR 20 R1810 F Payloads Rated payload Maximum payload Rated mass moment of inertia Rated supplementary load, base frame Maximum supplementary load, base frame Rated supplementary load, rotating column Maximum supplementary load, rotating column 20 kg 23 kg 0.36 kgm² 0 kg 0 kg 0 kg 20 kg Spez KR CYBERTECH V4 Issued: /181

72 Rated supplementary load, link arm Maximum supplementary load, link arm Rated supplementary load, arm Maximum supplementary load, arm 0 kg 15 kg 10 kg 10 kg Nominal distance to load center of gravity Lxy Lz 120 mm 150 mm Load center of gravity For all payloads, the load center of gravity refers to the distance from the face of the mounting flange on axis 6. Refer to the payload diagram for the nominal distance. Payload diagram Fig. 4-60: Load center of gravity NOTICE This loading curve corresponds to the maximum load capacity. Both values (payload and mass moment of inertia) must be checked in all cases. Exceeding this capacity will reduce the service life of the robot and overload the motors and the gears; in any such case KUKA Deutschland GmbH must be consulted beforehand. The values determined here are necessary for planning the robot application. For commissioning the robot, additional input data are required in accordance with the operating and programming instructions of the KUKA System Software. The mass inertia must be verified using KUKA.Load. It is imperative for the load data to be entered in the robot controller! 72/181 Spez KR CYBERTECH V4 Issued:

73 Fig. 4-61: KR 20 R1810 F, payload diagram The KR 20 R1810 F is designed for a rated payload of 20 kg in order to optimize the dynamic performance of the robot. With reduced load center distances, higher loads up to the maximum payload may be used. The specific load case must be verified using KUKA.Load. For further consultation, please contact KUKA Support. Mounting flange In-line wrist type ZH 8/12/16/20 Mounting flange Mounting flange (hole circle) Screw grade 12.9 Screw size Number of fastening threads 7 Clamping length Depth of engagement Locating element see drawing 50.0 mm M6 1.5 x nominal diameter min. 6 mm, max. 9 mm 6 H7 The mounting flange (>>> Fig. 4-62) is depicted with axes 4 and 6 in the zero position. The symbol X m indicates the position of the locating element (bushing) in the zero position. Spez KR CYBERTECH V4 Issued: /181

74 Fig. 4-62: Mounting flange Flange loads Due to the motion of the payload (e.g. tool) mounted on the robot, forces and torques act on the mounting flange. These forces and torques depend on the motion profile as well as the mass, load center of gravity and mass moment of inertia of the payload. The specified values refer to nominal payloads at the nominal distance and do not include safety factors. It is imperative for the load data to be entered in the robot controller. The robot controller takes the payload into consideration during path planning. A reduced payload does not necessarily result in lower forces and torques. The values are guide values determined by means of trial and simulation and refer to the most heavily loaded machine in the robot family. The actual forces and torques may differ due to internal and external influences on the mounting flange or a different point of application. It is therefore advisable to determine the exact forces and torques where necessary on site under the real conditions of the actual robot application. The operating values may occur permanently in the normal motion profile. It is advisable to rate the tool for its fatigue strength. The EMERGENCY STOP values may arise in the event of an Emergency Stop situation of the robot. As these should only occur very rarely during the service life of the robot, a static strength verification is usually sufficient. Fig. 4-63: Flange loads 74/181 Spez KR CYBERTECH V4 Issued:

75 Flange loads during operation F(a) 970 N F(r) 960 N M(k) 249 Nm M(g) 107 Nm Flange loads in the case of EMERGENCY STOP F(a) 1115 N F(r) 1280 N M(k) 164 Nm M(g) 326 Nm Axial force F(a), radial force F(r), tilting torque M(k), torque about mounting flange M(g) Supplementary load The robot can carry supplementary loads on the arm, link arm and rotating column. When mounting the supplementary loads, be careful to observe the maximum permissible total load. The dimensions and positions of the installation options can be seen in the following diagram. Fig. 4-64: Fastening the supplementary load, arm 1 Plane of rotation, axis 4 2 Mounting surface on arm Spez KR CYBERTECH V4 Issued: /181

76 Fig. 4-65: Fastening the supplementary load, link arm/rotating column 1 Mounting surface on link arm 2 Mounting surface on rotating column, both sides Foundation loads, KR 20 R1810 F Foundation loads The specified forces and moments already include the payload and the inertia force (weight) of the robot. Foundation loads for floor mounting position F(v normal) F(v max) F(h normal) F(h max) M(k normal) M(k max) M(r normal) M(r max) 4038 N 4434 N 2336 N 2988 N 3334 Nm 4177 Nm 1965 Nm 2361 Nm Foundation loads for ceiling mounting position F(v normal) F(v max) F(h normal) F(h max) M(k normal) M(k max) M(r normal) M(r max) 4104 N 4535 N 2272 N 2793 N 3642 Nm 4553 Nm 2017 Nm 2314 Nm Foundation loads for wall mounting position 76/181 Spez KR CYBERTECH V4 Issued:

77 F(v normal) F(v max) F(h normal) F(h max) M(k normal) M(k max) M(r normal) M(r max) 4265 N 4661 N 1464 N 2268 N 4603 Nm 5124 Nm 1739 Nm 2368 Nm Vertical force F(v), horizontal force F(h), tilting torque M(k), torque about axis 1 M(r) Fig. 4-66: Foundation loads WARNING Normal loads and maximum loads for the foundations are specified in the table. The maximum loads must be referred to when dimensioning the foundations and must be adhered to for safety reasons. Failure to observe this can result in personal injury and damage to property. The normal loads are average expected foundation loads. The actual loads are dependent on the program and on the robot loads and may therefore be greater or less than the normal loads. The supplementary loads (A1 and A2) are not taken into consideration in the calculation of the mounting base load. These supplementary loads must be taken into consideration for F v. Spez KR CYBERTECH V4 Issued: /181

78 4.8, KR 20 R1810 CR Basic data, KR 20 R1810 CR Basic data Number of axes 6 Number of controlled axes 6 Volume of working envelope 23.3 m³ Pose repeatability (ISO 9283) Weight Rated payload Maximum payload Maximum reach Protection rating (IEC 60529) Protection rating, in-line wrist (IEC 60529) Sound level Mounting position Footprint Hole pattern: mounting surface for kinematic system Permissible angle of inclination - Default color Controller Transformation name KR 20 R1810 CR ± 0.04 mm approx. 250 kg 20 kg 23 kg 1813 mm IP65 IP65 < 75 db (A) Floor; Ceiling; Wall; Desired angle mm x 370 mm S260 Base frame: stainless steel; Moving parts: traffic white (RAL 9016) KR C4 KR C4: #KR20R1810 C4 Ambient conditions Humidity class (EN 60204) - Classification of environmental conditions (EN ) Ambient temperature 3K3 During operation 5 C to 55 C (278 K to 328 K) During storage/transportation -20 C to 60 C (253 K to 333 K) For operation at low temperatures, it may be necessary to warm up the robot. 78/181 Spez KR CYBERTECH V4 Issued:

79 Connecting cables Cable designation Connector designation robot controller - robot Interface with robot Motor cable X20 - X30 Han-Yellock 60 Data cable X21 - X31 HAN Q12 Ground conductor / equipotential bonding 16 mm 2 (optional) M8 ring cable lug at both ends Cable lengths Standard Minimum bending radius 4 m, 7 m, 15 m, 25 m, 35 m, 50 m 5x D For detailed specifications of the connecting cables, see Description of the connecting cables Axis data, KR 20 R1810 CR Axis data Motion range A1 ±185 A2-185 / 65 A3-142 / 172 A4 ±350 A5 ±130 A6 ±350 Speed with rated payload A1 A2 A3 A4 A5 A6 200 /s 175 /s 190 /s 430 /s 430 /s 630 /s The direction of motion and the arrangement of the individual axes may be noted from the following diagram. Spez KR CYBERTECH V4 Issued: /181

80 Fig. 4-67: Direction of rotation of robot axes Mastering positions Mastering position A1 27 A2 90 A3 90 A4 0 A5 0 A6 0 Working envelope The following diagrams show the shape and size of the working envelope for these variants of this product family. The reference point for the working envelope is the intersection of axes 4 and 5. 80/181 Spez KR CYBERTECH V4 Issued:

81 Fig. 4-68: Working envelope, side view, KR 20 R1810 CR Fig. 4-69: Working envelope, top view, KR 20 R1810 CR Inclined installation The robot can installed anywhere from a 0 position (floor) to a 180 position (ceiling). The following figure shows the possible limitation of the motion range of axis 1, as a function of the angle of inclination of the robot. The inclination angles for the robot must be entered correctly into the controller if the robot is not operated in the floor-mounted position. Configuration of the angles is possible via WorkVisual. The inclination angles for an unchanged main working direction of the robot: Floor: A:0, B:0, C:0 Spez KR CYBERTECH V4 Issued: /181

82 Wall: A:0, B:90, C:0 Ceiling: A:0, B:0, C:180 CAUTION The inclined installation angles must be individually checked and entered. An incorrectly entered inclined installation angle can lead to unforeseen motion and/or to an overload and, potentially, damage to the robot. Fig. 4-70: Motion range of axis 1 with inclined installation Payloads, KR 20 R1810 CR Payloads Rated payload Maximum payload Rated mass moment of inertia Rated supplementary load, base frame Maximum supplementary load, base frame Rated supplementary load, rotating column Maximum supplementary load, rotating column 20 kg 23 kg 0.36 kgm² 0 kg 0 kg 0 kg 20 kg 82/181 Spez KR CYBERTECH V4 Issued:

83 Rated supplementary load, link arm Maximum supplementary load, link arm Rated supplementary load, arm Maximum supplementary load, arm 0 kg 15 kg 10 kg 15 kg Nominal distance to load center of gravity Lxy Lz 120 mm 150 mm Load center of gravity For all payloads, the load center of gravity refers to the distance from the face of the mounting flange on axis 6. Refer to the payload diagram for the nominal distance. Payload diagram Fig. 4-71: Load center of gravity NOTICE This loading curve corresponds to the maximum load capacity. Both values (payload and mass moment of inertia) must be checked in all cases. Exceeding this capacity will reduce the service life of the robot and overload the motors and the gears; in any such case KUKA Deutschland GmbH must be consulted beforehand. The values determined here are necessary for planning the robot application. For commissioning the robot, additional input data are required in accordance with the operating and programming instructions of the KUKA System Software. The mass inertia must be verified using KUKA.Load. It is imperative for the load data to be entered in the robot controller! Spez KR CYBERTECH V4 Issued: /181

84 Fig. 4-72: KR 20 R1810 CR, payload diagram The KR 20 R1810 CR is designed for a rated payload of 20 kg in order to optimize the dynamic performance of the robot. With reduced load center distances, higher loads up to the maximum payload may be used. The specific load case must be verified using KUKA.Load. For further consultation, please contact KUKA Support. Mounting flange In-line wrist type ZH 8/12/16/20 Mounting flange Mounting flange (hole circle) Screw grade 12.9 Screw size Number of fastening threads 7 Clamping length Depth of engagement Locating element see drawing 50.0 mm M6 1.5 x nominal diameter min. 6 mm, max. 9 mm 6 H7 The mounting flange (>>> Fig. 4-73) is depicted with axes 4 and 6 in the zero position. The symbol X m indicates the position of the locating element (bushing) in the zero position. 84/181 Spez KR CYBERTECH V4 Issued:

85 Fig. 4-73: Mounting flange Flange loads Due to the motion of the payload (e.g. tool) mounted on the robot, forces and torques act on the mounting flange. These forces and torques depend on the motion profile as well as the mass, load center of gravity and mass moment of inertia of the payload. The specified values refer to nominal payloads at the nominal distance and do not include safety factors. It is imperative for the load data to be entered in the robot controller. The robot controller takes the payload into consideration during path planning. A reduced payload does not necessarily result in lower forces and torques. The values are guide values determined by means of trial and simulation and refer to the most heavily loaded machine in the robot family. The actual forces and torques may differ due to internal and external influences on the mounting flange or a different point of application. It is therefore advisable to determine the exact forces and torques where necessary on site under the real conditions of the actual robot application. The operating values may occur permanently in the normal motion profile. It is advisable to rate the tool for its fatigue strength. The EMERGENCY STOP values may arise in the event of an Emergency Stop situation of the robot. As these should only occur very rarely during the service life of the robot, a static strength verification is usually sufficient. Fig. 4-74: Flange loads Spez KR CYBERTECH V4 Issued: /181

86 Flange loads during operation F(a) 970 N F(r) 960 N M(k) 249 Nm M(g) 107 Nm Flange loads in the case of EMERGENCY STOP F(a) 1115 N F(r) 1280 N M(k) 326 Nm M(g) 164 Nm Axial force F(a), radial force F(r), tilting torque M(k), torque about mounting flange M(g) Supplementary load The robot can carry supplementary loads on the arm, link arm and rotating column. When mounting the supplementary loads, be careful to observe the maximum permissible total load. The dimensions and positions of the installation options can be seen in the following diagram. Fig. 4-75: Fastening the supplementary load, arm 1 Plane of rotation, axis 4 2 Mounting surface on arm 86/181 Spez KR CYBERTECH V4 Issued:

87 Fig. 4-76: Fastening the supplementary load, link arm/rotating column 1 Mounting surface on link arm 2 Mounting surface on rotating column, both sides Foundation loads, KR 20 R1810 CR Foundation loads The specified forces and moments already include the payload and the inertia force (weight) of the robot. Foundation loads for floor mounting position F(v normal) F(v max) F(h normal) F(h max) M(k normal) M(k max) M(r normal) M(r max) 4038 N 4434 N 2336 N 2988 N 3334 Nm 4177 Nm 1965 Nm 2361 Nm Foundation loads for ceiling mounting position F(v normal) F(v max) F(h normal) F(h max) M(k normal) M(k max) M(r normal) M(r max) 4104 N 4535 N 2272 N 2793 N 3642 Nm 4553 Nm 2017 Nm 2314 Nm Foundation loads for wall mounting position Spez KR CYBERTECH V4 Issued: /181

88 F(v normal) F(v max) F(h normal) F(h max) M(k normal) M(k max) M(r normal) M(r max) 4265 N 4661 N 1464 N 2268 N 4603 Nm 5124 Nm 1739 Nm 2368 Nm Vertical force F(v), horizontal force F(h), tilting torque M(k), torque about axis 1 M(r) Fig. 4-77: Foundation loads WARNING Normal loads and maximum loads for the foundations are specified in the table. The maximum loads must be referred to when dimensioning the foundations and must be adhered to for safety reasons. Failure to observe this can result in personal injury and damage to property. The normal loads are average expected foundation loads. The actual loads are dependent on the program and on the robot loads and may therefore be greater or less than the normal loads. The supplementary loads (A1 and A2) are not taken into consideration in the calculation of the mounting base load. These supplementary loads must be taken into consideration for F v. 88/181 Spez KR CYBERTECH V4 Issued:

89 4.9, KR 22 R Basic data, KR 22 R1610 Basic data Number of axes 6 Number of controlled axes 6 KR 22 R1610 Volume of working envelope m³ Pose repeatability (ISO 9283) Weight Rated payload Maximum payload Maximum reach Protection rating (IEC 60529) Protection rating, in-line wrist (IEC 60529) Sound level Mounting position Footprint Hole pattern: mounting surface for kinematic system Permissible angle of inclination - ± 0.04 mm approx. 245 kg 22 kg 27 kg 1612 mm IP65 IP65 < 75 db (A) Floor; Ceiling; Wall; Desired angle mm x 370 mm S260 Default color Base frame: black (RAL 9005); Moving parts: KUKA orange 2567 Controller Transformation name KR C4 KR C4: KR22R1610 C4 Ambient conditions Humidity class (EN 60204) - Classification of environmental conditions (EN ) Ambient temperature 3K3 During operation 5 C to 55 C (278 K to 328 K) During storage/transportation -20 C to 60 C (253 K to 333 K) For operation at low temperatures, it may be necessary to warm up the robot. Spez KR CYBERTECH V4 Issued: /181

90 Connecting cables Cable designation Connector designation robot controller - robot Interface with robot Motor cable X20 - X30 Han-Yellock 60 Data cable X21 - X31 HAN Q12 Ground conductor / equipotential bonding 16 mm 2 (optional) M8 ring cable lug at both ends Cable lengths Standard Minimum bending radius 4 m, 7 m, 15 m, 25 m, 35 m, 50 m 5x D For detailed specifications of the connecting cables, see Description of the connecting cables Axis data, KR 22 R1610 Axis data Motion range A1 ±185 A2-185 / 65 A3-138 / 175 A4 ±350 A5 ±130 A6 ±350 Speed with rated payload A1 A2 A3 A4 A5 A6 200 /s 175 /s 190 /s 430 /s 430 /s 630 /s The direction of motion and the arrangement of the individual axes may be noted from the following diagram. 90/181 Spez KR CYBERTECH V4 Issued:

91 Fig. 4-78: Direction of rotation of robot axes Mastering positions Mastering position A1 27 A2 90 A3 90 A4 0 A5 0 A6 0 Working envelope The following diagrams show the shape and size of the working envelope for these variants of this product family. The reference point for the working envelope is the intersection of axes 4 and 5. Fig. 4-79: Working envelope, side view, KR 22 R1610 Spez KR CYBERTECH V4 Issued: /181

92 Fig. 4-80: Working envelope, top view, KR 22 R1610 Inclined installation The robot can installed anywhere from a 0 position (floor) to a 180 position (ceiling). The following figure shows the possible limitation of the motion range of axis 1, as a function of the angle of inclination of the robot. The inclination angles for the robot must be entered correctly into the controller if the robot is not operated in the floor-mounted position. Configuration of the angles is possible via WorkVisual. The inclination angles for an unchanged main working direction of the robot: Floor: A:0, B:0, C:0 Wall: A:0, B:90, C:0 Ceiling: A:0, B:0, C:180 CAUTION The inclined installation angles must be individually checked and entered. An incorrectly entered inclined installation angle can lead to unforeseen motion and/or to an overload and, potentially, damage to the robot. 92/181 Spez KR CYBERTECH V4 Issued:

93 Fig. 4-81: Motion range of axis 1 with inclined installation Payloads, KR 22 R1610 Payloads Rated payload Maximum payload Rated mass moment of inertia Rated supplementary load, base frame Maximum supplementary load, base frame Rated supplementary load, rotating column Maximum supplementary load, rotating column Rated supplementary load, link arm Maximum supplementary load, link arm Rated supplementary load, arm Maximum supplementary load, arm 22 kg 27 kg 0.36 kgm² 0 kg 0 kg 0 kg 20 kg 0 kg 15 kg 10 kg 15 kg Spez KR CYBERTECH V4 Issued: /181

94 Nominal distance to load center of gravity Lxy 120 mm Lz 150 mm Load center of gravity For all payloads, the load center of gravity refers to the distance from the face of the mounting flange on axis 6. Refer to the payload diagram for the nominal distance. Fig. 4-82: Load center of gravity Payload diagram NOTICE This loading curve corresponds to the maximum load capacity. Both values (payload and mass moment of inertia) must be checked in all cases. Exceeding this capacity will reduce the service life of the robot and overload the motors and the gears; in any such case KUKA Deutschland GmbH must be consulted beforehand. The values determined here are necessary for planning the robot application. For commissioning the robot, additional input data are required in accordance with the operating and programming instructions of the KUKA System Software. The mass inertia must be verified using KUKA.Load. It is imperative for the load data to be entered in the robot controller! 94/181 Spez KR CYBERTECH V4 Issued:

95 KR CYBERTECH Fig. 4-83: KR 22 R1610, payload diagram The KR 22 R1610 is designed for a rated payload of 22 kg in order to optimize the dynamic performance of the robot. With reduced load center distances, higher loads up to the maximum payload may be used. The specific load case must be verified using KUKA.Load. For further consultation, please contact KUKA Support. Mounting flange In-line wrist type ZH 16/22 Mounting flange see drawing Mounting flange (hole circle) 50.0 mm Screw grade 12.9 Screw size M6 Number of fastening threads 7 Clamping length 1.5 x nominal diameter Depth of engagement min. 6 mm, max. 9 mm Locating element 6 H7 The mounting flange (>>> Fig. 4-84) is depicted with axes 4 and 6 in the zero position. The symbol Xm indicates the position of the locating element (bushing) in the zero position. Spez KR CYBERTECH V4 Issued: /181

96 Fig. 4-84: Mounting flange Flange loads Due to the motion of the payload (e.g. tool) mounted on the robot, forces and torques act on the mounting flange. These forces and torques depend on the motion profile as well as the mass, load center of gravity and mass moment of inertia of the payload. The specified values refer to nominal payloads at the nominal distance and do not include safety factors. It is imperative for the load data to be entered in the robot controller. The robot controller takes the payload into consideration during path planning. A reduced payload does not necessarily result in lower forces and torques. The values are guide values determined by means of trial and simulation and refer to the most heavily loaded machine in the robot family. The actual forces and torques may differ due to internal and external influences on the mounting flange or a different point of application. It is therefore advisable to determine the exact forces and torques where necessary on site under the real conditions of the actual robot application. The operating values may occur permanently in the normal motion profile. It is advisable to rate the tool for its fatigue strength. The EMERGENCY STOP values may arise in the event of an Emergency Stop situation of the robot. As these should only occur very rarely during the service life of the robot, a static strength verification is usually sufficient. Fig. 4-85: Flange loads 96/181 Spez KR CYBERTECH V4 Issued:

97 Flange loads during operation F(a) 970 N F(r) 960 N M(k) 249 Nm M(g) 107 Nm Flange loads in the case of EMERGENCY STOP F(a) 1115 N F(r) 1280 N M(k) 326 Nm M(g) 164 Nm Axial force F(a), radial force F(r), tilting torque M(k), torque about mounting flange M(g) Supplementary load The robot can carry supplementary loads on the arm, link arm and rotating column. When mounting the supplementary loads, be careful to observe the maximum permissible total load. The dimensions and positions of the installation options can be seen in the following diagram. Fig. 4-86: Fastening the supplementary load, arm 1 Plane of rotation, axis 4 2 Mounting surface on arm Spez KR CYBERTECH V4 Issued: /181

98 Fig. 4-87: Fastening the supplementary load, link arm/rotating column 1 Mounting surface on link arm 2 Mounting surface on rotating column, both sides Foundation loads, KR 22 R1610 Foundation loads The specified forces and moments already include the payload and the inertia force (weight) of the robot. Foundation loads for floor mounting position F(v normal) F(v max) F(h normal) F(h max) M(k normal) M(k max) M(r normal) M(r max) 4038 N 4434 N 2336 N 2988 N 3334 Nm 4177 Nm 1965 Nm 2361 Nm Foundation loads for ceiling mounting position F(v normal) F(v max) F(h normal) F(h max) M(k normal) M(k max) M(r normal) M(r max) 4104 N 4535 N 2272 N 2793 N 3642 Nm 4553 Nm 2017 Nm 2314 Nm Foundation loads for wall mounting position 98/181 Spez KR CYBERTECH V4 Issued:

99 F(v normal) F(v max) F(h normal) F(h max) M(k normal) M(k max) M(r normal) M(r max) 4265 N 4661 N 1464 N 2268 N 4603 Nm 5124 Nm 1739 Nm 2368 Nm Vertical force F(v), horizontal force F(h), tilting torque M(k), torque about axis 1 M(r) Fig. 4-88: Foundation loads WARNING Normal loads and maximum loads for the foundations are specified in the table. The maximum loads must be referred to when dimensioning the foundations and must be adhered to for safety reasons. Failure to observe this can result in personal injury and damage to property. The normal loads are average expected foundation loads. The actual loads are dependent on the program and on the robot loads and may therefore be greater or less than the normal loads. The supplementary loads (A1 and A2) are not taken into consideration in the calculation of the mounting base load. These supplementary loads must be taken into consideration for F v. Spez KR CYBERTECH V4 Issued: /181

100 4.10 Plates and labels Plates and labels The following plates and labels (>>> Fig. 4-89) are attached to the robot. They must not be removed or rendered illegible. Illegible plates and labels must be replaced. The plates and labels depicted here are valid for all robots of this robot model. Fig. 4-89: Location of plates and labels Item 1 Description 2 High voltage Any improper handling can lead to contact with current-carrying components. Electric shock hazard! 3 Hot surface During operation of the robot, surface temperatures may be reached that could result in burn injuries. Protective gloves must be worn! Identification plate Content according to Machinery Directive. 100/181 Spez KR CYBERTECH V4 Issued:

101 Item 4 Description 5 Work on the robot Before start-up, transportation or maintenance, read and follow the assembly and operating instructions. 6 Transport position Before loosening the bolts of the mounting base, the robot must be in the transport position as indicated in the table. Risk of toppling! Danger zone Entering the danger zone of the robot is prohibited if the robot is in operation or ready for operation. Risk of injury! Spez KR CYBERTECH V4 Issued: /181

102 Item 7 Description Secure the axes Before exchanging any motor, secure the corresponding axis through safeguarding by suitable means/devices to protect against possible movement. The axis can move. Risk of crushing! 4.11 REACH duty to communicate information acc. to Art. 33 of Regulation (EC) 1907/2006 On the basis of the information provided by our suppliers, this product and its components contain no substances included on the "Candidate List" of Substances of Very High Concern (SVHCs) in a concentration exceeding 0.1 percent by mass Stopping distances and times General information Information concerning the data: The stopping distance is the angle traveled by the robot from the moment the stop signal is triggered until the robot comes to a complete standstill. The stopping time is the time that elapses from the moment the stop signal is triggered until the robot comes to a complete standstill. The data are given for the main axes A1, A2 and A3. The main axes are the axes with the greatest deflection. Superposed axis motions can result in longer stopping distances. Stopping distances and stopping times in accordance with DIN EN ISO , Annex B. Stop categories: Stop category 0» STOP 0 Stop category 1» STOP 1 according to IEC The values specified for Stop 0 are guide values determined by means of tests and simulation. They are average values which conform to the requirements of DIN EN ISO The actual stopping distances and stopping times may differ due to internal and external influences on the braking torque. It is therefore advisable to determine 102/181 Spez KR CYBERTECH V4 Issued:

103 the exact stopping distances and stopping times where necessary under the real conditions of the actual robot application. Measuring technique The stopping distances were measured using the robot-internal measuring technique. The wear on the brakes varies depending on the operating mode, robot application and the number of STOP 0 stops triggered. It is therefore advisable to check the stopping distance at least once a year Terms used Term m Phi POV Extension KCP Description Mass of the rated load and the supplementary load on the arm. Angle of rotation ( ) about the corresponding axis. This value can be entered in the controller via the KCP/smartPAD and can be displayed on the KCP/ smartpad. Program override (%) = velocity of the robot motion. This value can be entered in the controller via the KCP/smartPAD and can be displayed on the KCP/ smartpad. Distance (l in %) (>>> Fig. 4-90) between axis 1 and the intersection of axes 4 and 5. With parallelogram robots, the distance between axis 1 and the intersection of axis 6 and the mounting flange. KUKA Control Panel Teach pendant for the KR C2/KR C2 edition2005 The KCP has all the operator control and display functions required for operating and programming the industrial robot. smartpad Teach pendant for the KR C4 The smartpad has all the operator control and display functions required for operating and programming the industrial robot. Spez KR CYBERTECH V4 Issued: /181

104 Fig. 4-90: Extension Stopping distances and times, KR 8 R Stopping distances and stopping times for STOP 0, axis 1 to axis 3 The table shows the stopping distances and stopping times after a STOP 0 (category 0 stop) is triggered. The values refer to the following configuration: Extension l = 100% Program override POV = 100% Mass m = maximum load (rated load + supplementary load on arm) Stopping distance ( ) Stopping time (s) Axis Axis Axis /181 Spez KR CYBERTECH V4 Issued:

105 Stopping distances and stopping times for STOP 1, axis 1 Fig. 4-91: Stopping distances for STOP 1, axis 1 Spez KR CYBERTECH V4 Issued: /181

106 Fig. 4-92: Stopping times for STOP 1, axis 1 106/181 Spez KR CYBERTECH V4 Issued:

107 Stopping distances and stopping times for STOP 1, axis 2 Fig. 4-93: Stopping distances for STOP 1, axis 2 Spez KR CYBERTECH V4 Issued: /181

108 Fig. 4-94: Stopping times for STOP 1, axis 2 108/181 Spez KR CYBERTECH V4 Issued:

109 Stopping distances and stopping times for STOP 1, axis 3 Fig. 4-95: Stopping distances for STOP 1, axis 3 Fig. 4-96: Stopping times for STOP 1, axis Stopping distances and times, KR 12 R Stopping distances and stopping times for STOP 0, axis 1 to axis 3 The table shows the stopping distances and stopping times after a STOP 0 (category 0 stop) is triggered. The values refer to the following configuration: Extension l = 100% Program override POV = 100% Mass m = maximum load (rated load + supplementary load on arm) Spez KR CYBERTECH V4 Issued: /181

110 Stopping distance ( ) Axis Axis Axis Stopping time (s) 110/181 Spez KR CYBERTECH V4 Issued:

111 Stopping distances and stopping times for STOP 1, axis 1 Fig. 4-97: Stopping distances for STOP 1, axis 1 Spez KR CYBERTECH V4 Issued: /181

112 Fig. 4-98: Stopping times for STOP 1, axis 1 112/181 Spez KR CYBERTECH V4 Issued:

113 Stopping distances and stopping times for STOP 1, axis 2 Fig. 4-99: Stopping distances for STOP 1, axis 2 Spez KR CYBERTECH V4 Issued: /181

114 Fig : Stopping times for STOP 1, axis 2 114/181 Spez KR CYBERTECH V4 Issued:

115 Stopping distances and stopping times for STOP 1, axis 3 Fig : Stopping distances for STOP 1, axis 3 Fig : Stopping times for STOP 1, axis Stopping distances and times, KR 16 R Stopping distances and stopping times for STOP 0, axis 1 to axis 3 The table shows the stopping distances and stopping times after a STOP 0 (category 0 stop) is triggered. The values refer to the following configuration: Extension l = 100% Program override POV = 100% Mass m = maximum load (rated load + supplementary load on arm) Spez KR CYBERTECH V4 Issued: /181

116 Stopping distance ( ) Axis Axis Axis Stopping time (s) 116/181 Spez KR CYBERTECH V4 Issued:

117 Stopping distances and stopping times for STOP 1, axis 1 Fig : Stopping distances for STOP 1, axis 1 Spez KR CYBERTECH V4 Issued: /181

118 Fig : Stopping times for STOP 1, axis 1 118/181 Spez KR CYBERTECH V4 Issued:

119 Stopping distances and stopping times for STOP 1, axis 2 Fig : Stopping distances for STOP 1, axis 2 Spez KR CYBERTECH V4 Issued: /181

120 Fig : Stopping times for STOP 1, axis 2 120/181 Spez KR CYBERTECH V4 Issued:

121 Stopping distances and stopping times for STOP 1, axis 3 Fig : Stopping distances for STOP 1, axis 3 Fig : Stopping times for STOP 1, axis Stopping distances and times, KR 16 R Stopping distances and stopping times for STOP 0, axis 1 to axis 3 The table shows the stopping distances and stopping times after a STOP 0 (category 0 stop) is triggered. The values refer to the following configuration: Extension l = 100% Program override POV = 100% Mass m = maximum load (rated load + supplementary load on arm) Stopping distance ( ) Stopping time (s) Axis Axis Spez KR CYBERTECH V4 Issued: /181

122 Stopping distance ( ) Axis Stopping time (s) 122/181 Spez KR CYBERTECH V4 Issued:

123 Stopping distances and stopping times for STOP 1, axis 1 Fig : Stopping distances for STOP 1, axis 1 Spez KR CYBERTECH V4 Issued: /181

124 Fig : Stopping times for STOP 1, axis 1 124/181 Spez KR CYBERTECH V4 Issued:

125 Stopping distances and stopping times for STOP 1, axis 2 Fig : Stopping distances for STOP 1, axis 2 Spez KR CYBERTECH V4 Issued: /181

126 Fig : Stopping times for STOP 1, axis 2 126/181 Spez KR CYBERTECH V4 Issued:

127 Stopping distances and stopping times for STOP 1, axis 3 Fig : Stopping distances for STOP 1, axis 3 Fig : Stopping times for STOP 1, axis Stopping distances and times, KR 20 R1810 and KR 20 R1810 CRStopping distances Stopping distances and stopping times for STOP 0, axis 1 to axis 3 The table shows the stopping distances and stopping times after a STOP 0 (category 0 stop) is triggered. The values refer to the following configuration: Extension l = 100% Program override POV = 100% Mass m = maximum load (rated load + supplementary load on arm) Spez KR CYBERTECH V4 Issued: /181

128 Stopping distance ( ) Axis Axis Axis Stopping time (s) 128/181 Spez KR CYBERTECH V4 Issued:

129 Stopping distances and stopping times for STOP 1, axis 1 Fig : Stopping distances for STOP 1, axis 1 Spez KR CYBERTECH V4 Issued: /181

130 Fig : Stopping times for STOP 1, axis 1 130/181 Spez KR CYBERTECH V4 Issued:

131 Stopping distances and stopping times for STOP 1, axis 2 Fig : Stopping distances for STOP 1, axis 2 Spez KR CYBERTECH V4 Issued: /181

132 Fig : Stopping times for STOP 1, axis 2 132/181 Spez KR CYBERTECH V4 Issued:

133 Stopping distances and stopping times for STOP 1, axis 3 Fig : Stopping distances for STOP 1, axis 3 Fig : Stopping times for STOP 1, axis Stopping distances and times, KR 22 R Stopping distances and stopping times for STOP 0, axis 1 to axis 3 The table shows the stopping distances and stopping times after a STOP 0 (category 0 stop) is triggered. The values refer to the following configuration: Extension l = 100% Program override POV = 100% Mass m = maximum load (rated load + supplementary load on arm) Spez KR CYBERTECH V4 Issued: /181

134 Stopping distance ( ) Axis Axis Axis Stopping time (s) 134/181 Spez KR CYBERTECH V4 Issued:

135 Stopping distances and stopping times for STOP 1, axis 1 Fig : Stopping distances for STOP 1, axis 1 Spez KR CYBERTECH V4 Issued: /181

136 Fig : Stopping times for STOP 1, axis 1 136/181 Spez KR CYBERTECH V4 Issued:

137 Stopping distances and stopping times for STOP 1, axis 2 Fig : Stopping distances for STOP 1, axis 2 Spez KR CYBERTECH V4 Issued: /181

138 Fig : Stopping times for STOP 1, axis 2 138/181 Spez KR CYBERTECH V4 Issued:

139 Stopping distances and stopping times for STOP 1, axis 3 Fig : Stopping distances for STOP 1, axis 3 Fig : Stopping times for STOP 1, axis 3 Spez KR CYBERTECH V4 Issued: /181

140 Safety 5 Safety 5.1 General This Safety chapter refers to a mechanical component of an industrial robot. If the mechanical component is used together with a KUKA robot controller, the Safety chapter of the operating instructions or assembly instructions of the robot controller must be used! This contains all the information provided in this Safety chapter. It also contains additional safety information relating to the robot controller which must be observed. Where this Safety chapter uses the term industrial robot, this also refers to the individual mechanical component if applicable Liability Safety information The device described in this document is either an industrial robot or a component thereof. Components of the industrial robot: Manipulator Robot controller Teach pendant Connecting cables External axes (optional) e.g. linear unit, turn-tilt table, positioner Software Options, accessories The industrial robot is built using state-of-the-art technology and in accordance with the recognized safety rules. Nevertheless, misuse of the industrial robot may constitute a risk to life and limb or cause damage to the industrial robot and to other material property. The industrial robot may only be used in perfect technical condition in accordance with its designated use and only by safety-conscious persons who are fully aware of the risks involved in its operation. Use of the industrial robot is subject to compliance with this document and with the declaration of incorporation supplied together with the industrial robot. Any functional disorders affecting safety must be rectified immediately. Information about safety may not be construed against KUKA Deutschland GmbH. Even if all safety instructions are followed, this is not a guarantee that the industrial robot will not cause personal injuries or material damage. No modifications may be carried out to the industrial robot without the authorization of KUKA Deutschland GmbH. Additional components (tools, software, etc.), not supplied by KUKA Deutschland GmbH, may be integrated into the industrial robot. The user is liable for any damage these components may cause to the industrial robot or to other material property. In addition to the Safety chapter, this document contains further safety instructions. These must also be observed. 140/181 Spez KR CYBERTECH V4 Issued:

141 5.1.2 Intended use of the industrial robot The industrial robot is intended exclusively for the use designated in the Purpose chapter of the operating instructions or assembly instructions. Any use or application deviating from the intended use is deemed to be misuse and is not allowed. The manufacturer is not liable for any damage resulting from such misuse. The risk lies entirely with the user. Operation of the industrial robot in accordance with its intended use also requires compliance with the operating and assembly instructions for the individual components, with particular reference to the maintenance specifications. Safety Misuse Any use or application deviating from the intended use is deemed to be misuse and is not allowed. This includes e.g.: Use as a climbing aid Operation outside the specified operating parameters Operation without the required safety equipment EC declaration of conformity and declaration of incorporation EC declaration of conformity Declaration of incorporation The industrial robot constitutes partly completed machinery as defined by the EC Machinery Directive. The industrial robot may only be put into operation if the following preconditions are met: The industrial robot is integrated into a complete system. or: The industrial robot, together with other machinery, constitutes a complete system. or: All safety functions and safeguards required for operation in the complete machine as defined by the EC Machinery Directive have been added to the industrial robot. The complete system complies with the EC Machinery Directive. This has been confirmed by means of a conformity assessment procedure. The system integrator must issue an EC declaration of conformity for the complete system in accordance with the Machinery Directive. The EC declaration of conformity forms the basis for the CE mark for the system. The industrial robot must always be operated in accordance with the applicable national laws, regulations and standards. The robot controller has a CE mark in accordance with the EMC Directive and the Low Voltage Directive. The partly completed machinery is supplied with a declaration of incorporation in accordance with Annex II B of the EC Machinery Directive 2006/42/EC. The assembly instructions and a list of essential requirements complied with in accordance with Annex I are integral parts of this declaration of incorporation. The declaration of incorporation declares that the start-up of the partly completed machinery is not allowed until the partly completed machinery has been incorporated into machinery, or has been assembled with other parts to form machinery, and this machinery complies with the terms of the EC Machinery Directive, and the EC declaration of conformity is present in accordance with Annex II A. Spez KR CYBERTECH V4 Issued: /181

142 Safety Terms used Term Axis range Stopping distance Workspace Operator (User) Danger zone Service life KCP KUKA smartpad Manipulator Safety zone Safety options smartpad Stop category 0 Stop category 1 Stop category 2 System integrator (plant integrator) T1 Description Range of each axis, in degrees or millimeters, within which it may move. The axis range must be defined for each axis. Stopping distance = reaction distance + braking distance The stopping distance is part of the danger zone. The manipulator is allowed to move within its workspace. The workspace is derived from the individual axis ranges. The user of the industrial robot can be the management, employer or delegated person responsible for use of the industrial robot. The danger zone consists of the workspace and the stopping distances. The service life of a safety-relevant component begins at the time of delivery of the component to the customer. The service life is not affected by whether the component is used in a controller or elsewhere or not, as safety-relevant components are also subject to aging during storage KUKA Control Panel Teach pendant for the KR C2/KR C2 edition2005 The KCP has all the operator control and display functions required for operating and programming the industrial robot. see smartpad The robot arm and the associated electrical installations The safety zone is situated outside the danger zone. Generic term for options which make it possible to configure additional safe monitoring functions in addition to the standard safety functions. Example: SafeOperation Teach pendant for the KR C4 The smartpad has all the operator control and display functions required for operating and programming the industrial robot. The drives are deactivated immediately and the brakes are applied. The manipulator and any external axes (optional) perform path-oriented braking. Note: This stop category is called STOP 0 in this document. The manipulator and any external axes (optional) perform path-maintaining braking. The drives are deactivated after 1 s and the brakes are applied. Note: This stop category is called STOP 1 in this document. The drives are not deactivated and the brakes are not applied. The manipulator and any external axes (optional) are braked with a normal braking ramp. Note: This stop category is called STOP 2 in this document. System integrators are people who safely integrate the industrial robot into a complete system and commission it. Test mode, Manual Reduced Velocity (<= 250 mm/s) 142/181 Spez KR CYBERTECH V4 Issued:

143 Term T2 External axis Description Test mode, Manual High Velocity (> 250 mm/s permissible) Axis of motion that does not belong to the manipulator, yet is controlled with the same controller. e.g. KUKA linear unit, turn-tilt table, Posiflex Safety 5.2 Personnel The following persons or groups of persons are defined for the industrial robot: User Personnel All persons working with the industrial robot must have read and understood the industrial robot documentation, including the safety chapter. User The user must observe the labor laws and regulations. This includes e.g.: The user must comply with his monitoring obligations. The user must carry out briefing at defined intervals. Personnel Personnel must be instructed, before any work is commenced, in the type of work involved and what exactly it entails as well as any hazards which may exist. Instruction must be carried out regularly. Instruction is also required after particular incidents or technical modifications. Personnel includes: System integrator Operators, subdivided into: Start-up, maintenance and service personnel Operating personnel Cleaning personnel Installation, exchange, adjustment, operation, maintenance and repair must be performed only as specified in the operating or assembly instructions for the relevant component of the industrial robot and only by personnel specially trained for this purpose. System integrator The industrial robot is safely integrated into a complete system by the system integrator. The system integrator is responsible for the following tasks: Installing the industrial robot Connecting the industrial robot Performing risk assessment Implementing the required safety functions and safeguards Issuing the EC declaration of conformity Attaching the CE mark Creating the operating instructions for the system Spez KR CYBERTECH V4 Issued: /181

144 Safety Operators The operator must meet the following preconditions: The operator must be trained for the work to be carried out. Work on the system must only be carried out by qualified personnel. These are people who, due to their specialist training, knowledge and experience, and their familiarization with the relevant standards, are able to assess the work to be carried out and detect any potential hazards. Work on the electrical and mechanical equipment of the industrial robot may only be carried out by specially trained personnel. 5.3 Workspace, safety zone and danger zone Workspaces are to be restricted to the necessary minimum size. A workspace must be safeguarded using appropriate safeguards. The safeguards (e.g. safety gate) must be situated inside the safety zone. In the case of a stop, the manipulator and external axes (optional) are braked and come to a stop within the danger zone. The danger zone consists of the workspace and the stopping distances of the manipulator and external axes (optional). It must be safeguarded by means of physical safeguards to prevent danger to persons or the risk of material damage. 5.4 Overview of protective equipment The protective equipment of the mechanical component may include: Mechanical end stops Mechanical axis limitation (optional) Release device (optional) Brake release device (optional) Labeling of danger areas Not all equipment is relevant for every mechanical component Mechanical end stops Depending on the robot variant, the axis ranges of the main and wrist axes of the manipulator are partially limited by mechanical end stops. Additional mechanical end stops can be installed on the external axes. WARNING If the manipulator or an external axis hits an obstruction or a mechanical end stop or mechanical axis limitation, the manipulator can no longer be operated safely. The manipulator must be taken out of operation and KUKA Deutschland GmbH must be consulted before it is put back into operation Mechanical axis limitation (optional) Some manipulators can be fitted with mechanical axis limitation systems in axes A1 to A3. The axis limitation systems restrict the working range to 144/181 Spez KR CYBERTECH V4 Issued:

145 the required minimum. This increases personal safety and protection of the system. In the case of manipulators that are not designed to be fitted with mechanical axis limitation, the workspace must be laid out in such a way that there is no danger to persons or material property, even in the absence of mechanical axis limitation. If this is not possible, the workspace must be limited by means of photoelectric barriers, photoelectric curtains or obstacles on the system side. There must be no shearing or crushing hazards at the loading and transfer areas. This option is not available for all robot models. Information on specific robot models can be obtained from KUKA Deutschland GmbH. Safety Options for moving the manipulator without drive energy Description The system user is responsible for ensuring that the training of personnel with regard to the response to emergencies or exceptional situations also includes how the manipulator can be moved without drive energy. The following options are available for moving the manipulator without drive energy after an accident or malfunction: Release device (optional) The release device can be used for the main axis drive motors and, depending on the robot variant, also for the wrist axis drive motors. Brake release device (option) The brake release device is designed for robot variants whose motors are not freely accessible. Moving the wrist axes directly by hand There is no release device available for the wrist axes of variants in the low payload category. This is not necessary because the wrist axes can be moved directly by hand. Information about the options available for the various robot models and about how to use them can be found in the assembly and operating instructions for the robot or requested from KUKA Deutschland GmbH. NOTICE Moving the manipulator without drive energy can damage the motor brakes of the axes concerned. The motor must be replaced if the brake has been damaged. The manipulator may therefore be moved without drive energy only in emergencies, e.g. for rescuing persons Labeling on the industrial robot All plates, labels, symbols and marks constitute safety-relevant parts of the industrial robot. They must not be modified or removed. Labeling on the industrial robot consists of: Identification plates Warning signs Safety symbols Spez KR CYBERTECH V4 Issued: /181

146 Safety Designation labels Cable markings Rating plates Further information is contained in the technical data of the operating instructions or assembly instructions of the components of the industrial robot. 5.5 Safety measures General safety measures The industrial robot may only be used in perfect technical condition in accordance with its intended use and only by safety-conscious persons. Operator errors can result in personal injury and damage to property. It is important to be prepared for possible movements of the industrial robot even after the robot controller has been switched off and locked out. Incorrect installation (e.g. overload) or mechanical defects (e.g. brake defect) can cause the manipulator or external axes to sag. If work is to be carried out on a switched-off industrial robot, the manipulator and external axes must first be moved into a position in which they are unable to move on their own, whether the payload is mounted or not. If this is not possible, the manipulator and external axes must be secured by appropriate means. DANGER In the absence of operational safety functions and safeguards, the industrial robot can cause personal injury or material damage. If safety functions or safeguards are dismantled or deactivated, the industrial robot may not be operated. DANGER Standing underneath the robot arm can cause death or injuries. For this reason, standing underneath the robot arm is prohibited! KCP/smartPAD CAUTION The motors reach temperatures during operation which can cause burns to the skin. Contact must be avoided. Appropriate safety precautions must be taken, e.g. protective gloves must be worn. The user must ensure that the industrial robot is only operated with the KCP/smartPAD by authorized persons. If more than one KCP/smartPAD is used in the overall system, it must be ensured that each device is unambiguously assigned to the corresponding industrial robot. They must not be interchanged. WARNING The operator must ensure that decoupled KCPs/smartPADs are immediately removed from the system and stored out of sight and reach of personnel working on the industrial robot. This serves to prevent operational and non-operational EMERGENCY STOP devices from becoming interchanged. Failure to observe this precaution may result in death, severe injuries or considerable damage to property. 146/181 Spez KR CYBERTECH V4 Issued:

147 External keyboard, external mouse An external keyboard and/or external mouse may only be used if the following conditions are met: Safety Start-up or maintenance work is being carried out. The drives are switched off. There are no persons in the danger zone. The KCP/smartPAD must not be used as long as an external keyboard and/or external mouse are connected to the control cabinet. The external keyboard and/or external mouse must be removed from the control cabinet as soon as the start-up or maintenance work is completed or the KCP/smartPAD is connected. Modifications After modifications to the industrial robot, checks must be carried out to ensure the required safety level. The valid national or regional work safety regulations must be observed for this check. The correct functioning of all safety functions must also be tested. New or modified programs must always be tested first in Manual Reduced Velocity mode (T1). After modifications to the industrial robot, existing programs must always be tested first in Manual Reduced Velocity mode (T1). This applies to all components of the industrial robot and includes e.g. modifications of the external axes or to the software and configuration settings. Faults The following tasks must be carried out in the case of faults in the industrial robot: Switch off the robot controller and secure it (e.g. with a padlock) to prevent unauthorized persons from switching it on again. Indicate the fault by means of a label with a corresponding warning (tagout). Keep a record of the faults. Eliminate the fault and carry out a function test Transportation Manipulator Robot controller The prescribed transport position of the manipulator must be observed. Transportation must be carried out in accordance with the operating instructions or assembly instructions of the robot. Avoid vibrations and impacts during transportation in order to prevent damage to the manipulator. The prescribed transport position of the robot controller must be observed. Transportation must be carried out in accordance with the operating instructions or assembly instructions of the robot controller. Avoid vibrations and impacts during transportation in order to prevent damage to the robot controller. Spez KR CYBERTECH V4 Issued: /181

148 Safety External axis (optional) The prescribed transport position of the external axis (e.g. KUKA linear unit, turn-tilt table, positioner) must be observed. Transportation must be carried out in accordance with the operating instructions or assembly instructions of the external axis Start-up and recommissioning Before starting up systems and devices for the first time, a check must be carried out to ensure that the systems and devices are complete and operational, that they can be operated safely and that any damage is detected. The valid national or regional work safety regulations must be observed for this check. The correct functioning of all safety circuits must also be tested. The passwords for logging onto the KUKA System Software as Expert and Administrator must be changed before start-up and must only be communicated to authorized personnel. WARNING The robot controller is preconfigured for the specific industrial robot. If cables are interchanged, the manipulator and the external axes (optional) may receive incorrect data and can thus cause personal injury or material damage. If a system consists of more than one manipulator, always connect the connecting cables to the manipulators and their corresponding robot controllers. If additional components (e.g. cables), which are not part of the scope of supply of KUKA Deutschland GmbH, are integrated into the industrial robot, the user is responsible for ensuring that these components do not adversely affect or disable safety functions. Function test NOTICE If the internal cabinet temperature of the robot controller differs greatly from the ambient temperature, condensation can form, which may cause damage to the electrical components. Do not put the robot controller into operation until the internal temperature of the cabinet has adjusted to the ambient temperature. The following tests must be carried out before start-up and recommissioning: It must be ensured that: The industrial robot is correctly installed and fastened in accordance with the specifications in the documentation. There is no damage to the robot that could be attributed to external forces. Example: Dents or abrasion that could be caused by an impact or collision. 148/181 Spez KR CYBERTECH V4 Issued:

149 WARNING In the case of such damage, the affected components must be exchanged. In particular, the motor and counterbalancing system must be checked carefully. External forces can cause non-visible damage. For example, it can lead to a gradual loss of drive power from the motor, resulting in unintended movements of the manipulator. Death, injuries or considerable damage to property may otherwise result. Safety There are no foreign bodies or loose parts on the industrial robot. All required safety equipment is correctly installed and operational. The power supply ratings of the industrial robot correspond to the local supply voltage and mains type. The ground conductor and the equipotential bonding cable are sufficiently rated and correctly connected. The connecting cables are correctly connected and the connectors are locked Manual mode Manual mode is the mode for setup work. Setup work is all the tasks that have to be carried out on the industrial robot to enable automatic operation. Setup work includes: Jog mode Teaching Programming Program verification The following must be taken into consideration in manual mode: If the drives are not required, they must be switched off to prevent the manipulator or the external axes (optional) from being moved unintentionally. New or modified programs must always be tested first in Manual Reduced Velocity mode (T1). The manipulator, tooling or external axes (optional) must never touch or project beyond the safety fence. Workpieces, tooling and other objects must not become jammed as a result of the industrial robot motion, nor must they lead to short-circuits or be liable to fall off. All setup work must be carried out, where possible, from outside the safeguarded area. If the setup work has to be carried out inside the safeguarded area, the following must be taken into consideration: In Manual Reduced Velocity mode (T1): If it can be avoided, there must be no other persons inside the safeguarded area. If it is necessary for there to be several persons inside the safeguarded area, the following must be observed: Each person must have an enabling device. All persons must have an unimpeded view of the industrial robot. Eye-contact between all persons must be possible at all times. Spez KR CYBERTECH V4 Issued: /181

150 Safety The operator must be so positioned that he can see into the danger area and get out of harm s way. In Manual High Velocity mode (T2): This mode may only be used if the application requires a test at a velocity higher than possible in T1 mode. Teaching and programming are not permissible in this operating mode. Before commencing the test, the operator must ensure that the enabling devices are operational. The operator must be positioned outside the danger zone. There must be no other persons inside the safeguarded area. It is the responsibility of the operator to ensure this Automatic mode Automatic mode is only permissible in compliance with the following safety measures: All safety equipment and safeguards are present and operational. There are no persons in the system. The defined working procedures are adhered to. If the manipulator or an external axis (optional) comes to a standstill for no apparent reason, the danger zone must not be entered until an EMER- GENCY STOP has been triggered Maintenance and repair After maintenance and repair work, checks must be carried out to ensure the required safety level. The valid national or regional work safety regulations must be observed for this check. The correct functioning of all safety functions must also be tested. The purpose of maintenance and repair work is to ensure that the system is kept operational or, in the event of a fault, to return the system to an operational state. Repair work includes troubleshooting in addition to the actual repair itself. The following safety measures must be carried out when working on the industrial robot: Carry out work outside the danger zone. If work inside the danger zone is necessary, the user must define additional safety measures to ensure the safe protection of personnel. Switch off the industrial robot and secure it (e.g. with a padlock) to prevent it from being switched on again. If it is necessary to carry out work with the robot controller switched on, the user must define additional safety measures to ensure the safe protection of personnel. If it is necessary to carry out work with the robot controller switched on, this may only be done in operating mode T1. Label the system with a sign indicating that work is in progress. This sign must remain in place, even during temporary interruptions to the work. The EMERGENCY STOP devices must remain active. If safety functions or safeguards are deactivated during maintenance or repair work, they must be reactivated immediately after the work is completed. 150/181 Spez KR CYBERTECH V4 Issued:

151 DANGER Before work is commenced on live parts of the robot system, the main switch must be turned off and secured against being switched on again. The system must then be checked to ensure that it is deenergized. It is not sufficient, before commencing work on live parts, to execute an EMERGENCY STOP or a safety stop, or to switch off the drives, as this does not disconnect the robot system from the mains power supply. Parts remain energized. Death or severe injuries may result. Safety Faulty components must be replaced using new components with the same article numbers or equivalent components approved by KUKA Deutschland GmbH for this purpose. Cleaning and preventive maintenance work is to be carried out in accordance with the operating instructions. Robot controller Counterbalancing system Hazardous substances Even when the robot controller is switched off, parts connected to peripheral devices may still carry voltage. The external power sources must therefore be switched off if work is to be carried out on the robot controller. The ESD regulations must be adhered to when working on components in the robot controller. Voltages in excess of 50 V (up to 600 V) can be present in various components for several minutes after the robot controller has been switched off! To prevent life-threatening injuries, no work may be carried out on the industrial robot in this time. Water and dust must be prevented from entering the robot controller. Some robot variants are equipped with a hydropneumatic, spring or gas cylinder counterbalancing system. The hydropneumatic and gas cylinder counterbalancing systems are pressure equipment and, as such, are subject to obligatory equipment monitoring and the provisions of the Pressure Equipment Directive. The user must comply with the applicable national laws, regulations and standards pertaining to pressure equipment. Inspection intervals in Germany in accordance with Industrial Safety Order, Sections 14 and 15. Inspection by the user before commissioning at the installation site. The following safety measures must be carried out when working on the counterbalancing system: The manipulator assemblies supported by the counterbalancing systems must be secured. Work on the counterbalancing systems must only be carried out by qualified personnel. The following safety measures must be carried out when handling hazardous substances: Avoid prolonged and repeated intensive contact with the skin. Avoid breathing in oil spray or vapors. Clean skin and apply skin cream. Spez KR CYBERTECH V4 Issued: /181

152 Safety To ensure safe use of our products, we recommend regularly requesting up-to-date safety data sheets for hazardous substances Decommissioning, storage and disposal The industrial robot must be decommissioned, stored and disposed of in accordance with the applicable national laws, regulations and standards. 5.6 Applied norms and regulations Name/Edition 2006/42/EU: /68/EU:2014 EN ISO 13850:2015 EN ISO :2015 EN ISO :2012 EN ISO 12100:2010 EN ISO :2011 EN 614-1:2006+A1:2009 EN :2005 EN : A1:2011 EN :2006/ A1:2009 Definition Machinery Directive: Directive 2006/42/EC of the European Parliament and of the Council of 17 May 2006 on machinery, and amending Directive 95/16/EC (recast) Pressure Equipment Directive: Directive 2014/68/EU of the European Parliament and of the Council dated 15 May 2014 on the approximation of the laws of the Member States concerning pressure equipment (Only applicable for robots with hydropneumatic counterbalancing system.) Safety of machinery: Emergency stop - Principles for design Safety of machinery: Safety-related parts of control systems - Part 1: General principles of design Safety of machinery: Safety-related parts of control systems - Part 2: Validation Safety of machinery: General principles of design, risk assessment and risk reduction Industrial robots Safety requirements: Part 1: Robots Note: Content equivalent to ANSI/RIA R , Part 1 Safety of machinery: Ergonomic design principles - Part 1: Terms and general principles Electromagnetic compatibility (EMC): Part 6-2: Generic standards; Immunity for industrial environments Electromagnetic compatibility (EMC): Part 6-4: Generic standards; Emission standard for industrial environments Safety of machinery: 152/181 Spez KR CYBERTECH V4 Issued:

153 Electrical equipment of machines - Part 1: General requirements Safety Spez KR CYBERTECH V4 Issued: /181

154 Planning 6 Planning 6.1 Information for planning In the planning and design phase, care must be taken regarding the functions or applications to be executed by the kinematic system. The following conditions can lead to premature wear. They necessitate shorter maintenance intervals and/or earlier exchange of components. In addition, the permissible operating parameters specified in the technical data must be taken into account and observed during planning. Continuous operation near temperature limits or in abrasive environments Continuous operation close to the performance limits, e.g. high rpm of an axis High duty cycle of individual axes Monotonous motion profiles, e.g. short, frequently recurring axis motions Static axis positions, e.g. continuous vertical position of a wrist axis External forces (process forces) acting on the robot If one or more of these conditions are to apply during operation of the kinematic system, KUKA Deutschland GmbH must be consulted. If the robot reaches its corresponding operation limit or if it is operated near the limit for a period of time, the built-in monitoring functions come into effect and the robot is automatically switched off. This protective function can limit the availability of the robot system. 6.2 Mounting base with centering Description The mounting base with centering is used when the robot is fastened to the floor, i.e. directly on a concrete foundation. The mounting base with centering consists of: Bedplates Resin-bonded anchors (chemical anchors) Fastening elements This mounting variant requires a level and smooth surface on a concrete foundation with adequate load bearing capacity. The concrete foundation must be able to accommodate the forces occurring during operation. There must be no layers of insulation or screed between the bedplates and the concrete foundation. The minimum dimensions must be observed. 154/181 Spez KR CYBERTECH V4 Issued:

155 Planning Fig. 6-1: Mounting base 1 Bedplate 2 Hexagon bolt with lock washer 3 Resin-bonded anchor 4 Locating pin Grade of concrete for foundations Dimensioned drawing When producing foundations from concrete, observe the load-bearing capacity of the ground and the country-specific construction regulations. There must be no layers of insulation or screed between the bedplate/ bedplates and the concrete foundation. The quality of the concrete must meet the requirements of the following standard: C20/25 according to DIN EN 206-1:2001/DIN :2008 The following illustration (>>> Fig. 6-2) provides all the necessary information on the mounting base, together with the required foundation data. The specified foundation dimensions refer to the safe transmission of the foundation loads into the foundation and not to the stability of the foundation. Spez KR CYBERTECH V4 Issued: /181

156 Planning Fig. 6-2: Mounting base, dimensioned drawing 1 Locating pin 2 Hexagon bolt with lock washer 3 Resin-bonded anchor 4 Bedplate To ensure that the anchor forces are safely transmitted to the foundation, observe the dimensions for concrete foundations specified in the following illustration. NOTICE The dimensions specified for the distance to the edge are valid for nonreinforced or normally reinforced concrete without verification of concrete edge failure. For safety against concrete edge failure in accordance with ETAG 001 Annex C, the concrete foundation must be provided with an appropriate edge reinforcement. 156/181 Spez KR CYBERTECH V4 Issued:

157 Planning Fig. 6-3: Cross-section of foundations 1 Hexagon bolt with lock washer 2 Bedplate 3 Concrete foundation 6.3 Machine frame mounting Description The machine frame mounting (>>> Fig. 6-4) with centering is used for installing the robot on a steel structure provided by the customer or on the carriage of a KUKA linear unit. The mounting surface for the robot must be machined and of an appropriate quality. The robot is fastened to the machine frame mounting option using 4 Allen screws. Two support pins are used for centering. The steel structure used by the customer must be designed in such a way that the forces generated (mounting base load, maximum load (>>> 4 "" Page 11)) are safely transmitted via the screw connection and the necessary stiffness is ensured. The specified surface values and tightening torques must be observed. The following values must be taken into consideration in the design: Bolt force: Fs = 62 kn Stripping safety: The material of the substructure must be selected so that the stripping safety is ensured (e.g. S355J2G3). The machine frame mounting assembly consists of: Locating pin Hexagon bolts with lock washers Spez KR CYBERTECH V4 Issued: /181

158 Planning Dimensioned drawing Fig. 6-4: Machine frame mounting 1 Machine frame 2 Hexagon bolt with lock washer 3 Mounting surface, machined 4 Locating pin, flat-sided 5 Locating pin, round The following diagram contains all the necessary information that must be observed when preparing the mounting surface and the holes (>>> Fig. 6-5). 158/181 Spez KR CYBERTECH V4 Issued:

159 Planning Fig. 6-5: Machine frame mounting, dimensioned drawing 1 Hexagon bolt with lock washer 2 Locating pin 3 Mounting surface, machined 6.4 Connecting cables and interfaces Connecting cables The connecting cables comprise all the cables for transferring energy and signals between the robot and the robot controller. They are connected to the robot junction boxes with connectors. The set of connecting cables comprises: The following diagram provides an overview of the available connecting cables. (>>> Fig. 6-6) Spez KR CYBERTECH V4 Issued: /181

160 Planning Fig. 6-6: Connecting cables, overview The following connecting cables are available and can be used irrespective of the cable set in the robot: Motor cable, X20 - X30 Data cable, X21 - X31 Ground conductor (optional) Cable lengths of 4 m, 7 m, 15 m, 25 m, 35 m and 50 m are available as standard. The maximum length of the connecting cables must not exceed 50 m. Thus if the robot is operated on a linear unit which has its own energy supply chain, these cable lengths must also be taken into account. For the connecting cables, an additional ground conductor is always required to provide a low-resistance connection between the robot and the control cabinet in accordance with DIN EN A second ground conductor must additionally be installed between the robot and the system. The ground conductors are connected via ring cable lugs. The threaded bolts for connecting the two ground conductors are located on the base frame of the robot. The following points must be observed when planning and routing the connecting cables: The bending radius for fixed routing must not be less than 150 mm for motor cables and 60 mm for control cables. Protect cables against exposure to mechanical stress. Route the cables without mechanical stress no tensile forces on the connectors Cables are only to be installed indoors. Observe the permissible temperature range (fixed installation) of 263 K (-10 C) to 343 K (+70 C). Route the motor cables and the data cables separately in metal ducts; if necessary, additional measures must be taken to ensure electromagnetic compatibility (EMC). 160/181 Spez KR CYBERTECH V4 Issued:

161 Planning Fig. 6-7: Interfaces on the robot 1 Interface A6, tool 2 Interface A3, arm 3 Data cable connection X31 4 Motor cable connection X30 5 Interface A1, base frame Interface A1 Interface A1 on the base frame is illustrated below: Fig. 6-8: Interface A1 1 Mastering cable X32 4 External axis XP7.1 2 Motor cable X30 5 Data cable X31 3 External axis XP8.1 Spez KR CYBERTECH V4 Issued: /181

162 Planning Interface for energy supply system The robot can be equipped with an energy supply system between axis 1 and axis 3 and a second energy supply system between axis 3 and axis 6. The A1 interface required for this is located on the rear of the base frame, the A3 interface is located on the side of the arm and the interface for axis 6 is located on the robot tool. Depending on the application, the interfaces differ in design and scope. They can be equipped e.g. with connections for cables and hoses. Detailed information on the connector pin allocation, threaded unions, etc. is given in separate documentation. 162/181 Spez KR CYBERTECH V4 Issued:

163 7 Transportation 7.1 Transporting the robot Move the robot into its transport position (>>> Fig. 7-1) each time it is transported. It must be ensured that the robot is stable while it is being transported. The robot must remain in its transport position until it has been fastened in position. Before the robot is lifted, it must be ensured that it is free from obstructions. Remove all transport safeguards, such as nails and screws, in advance. First remove any rust or glue on contact surfaces. Transportation Transport position The transport position is the same for all robots of this model. The robot is in the transport position when the axes are in the following positions: Axis A1 A2 A3 A4 A5 A6 Angle 0º -138º +139º 0º +90º 0º Transport dimensions Fig. 7-1: Transport position The transport dimensions for the robot can be noted from the following figures. The position of the center of gravity and the weight vary according to the specific configuration. The specified dimensions refer to the robot without equipment. Spez KR CYBERTECH V4 Issued: /181

164 Transportation Fig. 7-2: Transport dimensions 1 Robot 3 Fork slots 2 Center of gravity Transport dimensions and centers of gravity Robot A B C D E F G KR 8 R KR 12 R KR 16 R KR 16 R KR 20 R1810 KR 20 R1810 F KR 20 R1810 CR KR 22 R Transportation The robot can be transported by means of crane or using a fork lift truck and fork slots (optional). WARNING Transportation by fork lift truck Use of unsuitable handling equipment may result in damage to the robot or injury to persons. Only use authorized handling equipment with a sufficient load-bearing capacity. Only transport the robot in the manner specified here. For transport by fork lift truck (>>> Fig. 7-3), the 2 fork slots (optional) must be properly and fully installed. The robot must be in the transport position. 164/181 Spez KR CYBERTECH V4 Issued:

165 Further information about the fork slots can be found in the documentation of the Load Lifting Attachment with Fork Slot. Transportation Fig. 7-3: Transportation by fork lift truck Transportation using lifting tackle The floor-mounted robot can be transported using a crane and lifting tackle (>>> Fig. 7-4). For this, it must be in the transport position. The lifting tackle is attached to eyebolts that are screwed into the rotating column and into the base frame. All ropes of the lifting tackle must be long enough and must be routed in such a way that the robot is not damaged. Installed tools and pieces of equipment can cause undesirable shifts in the center of gravity. These must therefore be removed if necessary. The eyebolts must be removed from the rotating column after transportation. WARNING The robot may tip during transportation. Risk of personal injury and damage to property. If the robot is being transported using lifting tackle, special care must be exercised to prevent it from tipping. Additional safeguarding measures must be taken. It is forbidden to pick up the robot in any other way using a crane! Fig. 7-4: Transportation by crane 1 Lifting tackle assembly 2 Leg G1 3 Leg G3 Spez KR CYBERTECH V4 Issued: /181

166 Transportation 4 M10 eyebolt, rotating column, front 5 M10 eyebolt, base frame, left 6 Leg G2 7 M10 eyebolt, base frame, right 166/181 Spez KR CYBERTECH V4 Issued:

167 8 Options Options 8.1 Release device (optional) Description The release device can be used to move the manipulator manually after an accident or malfunction. The release device can be used for the motors of axes 1 to 5. It cannot be used for axis 6, as this motor is not accessible. It is only for use in exceptional circumstances and emergencies (e.g. for freeing people). The release device is mounted on the base frame of the manipulator. This assembly also includes a ratchet and a set of plates with one plate for each motor. The plate specifies the direction of rotation for the ratchet and shows the corresponding direction of motion of the manipulator. 8.2 Booster frames The booster frame is fastened to the floor and raises the installation position of a robot. The following booster frames are available for the KR CY- BERTECH product family: Booster frame S260 S310 H1000 Booster frame S260 S310 H1200 Booster frame S260 S310 H1400 Booster frame S260 S310 H1600 Booster frame S260 S310 H1800 Booster frame S260 S310 H2000 Booster frame S260 S310 H200 Booster frame S260 S310 H400 Booster frame S260 S310 H600 The holes marked in the following diagram must be used for fastening the robot (>>> Fig. 8-1). Spez KR CYBERTECH V4 Issued: /181

168 Options Fig. 8-1: Boreholes Basic data, Booster frame S260 S310 H1000 Article number Shape Height Hole pattern: mounting surface for kinematic system Footprint Weight round 1000 mm S260; S310 Ø650 mm 129 kg Default color Stone gray (RAL 7030) Basic data, Booster frame S260 S310 H1200 Article number Shape Height Hole pattern: mounting surface for kinematic system Footprint Weight round 1200 mm S260; S310 Ø650 mm 144 kg Default color Stone gray (RAL 7030) Basic data, Booster frame S260 S310 H1400 Article number Shape Height Hole pattern: mounting surface for kinematic system round 1400 mm S260; S /181 Spez KR CYBERTECH V4 Issued: